HAZARD ANALYSIS & CRITICAL

CONTROL POINT
Based on :

SNI CAC / RCP

1:2011
Code of Practice –
General Principles of
Food Hygiene
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 Training
Objectives
1. Understanding the role and importance of
HACCP in the organization/company
2. Understanding the HACCP implementation
method
3. Able to develop SOP/procedures for the
implementation of HACCP
4. Able to implement HACCP effectively
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Training Agenda

1. Introduction to HACCP History of HACCP; HACCP regulations in

the European Union; Objectives of HACCP Implementation;
2. HACCP Principles;
3. Hazard Potential Analysis;
4. HACCP System Implementation Guide; HACCP System Stages;
HACCP Team Development;
5. Product Description;
6. Identification of the Purpose of Use;
7. Preparation of Flowcharts;
8. Cross Confirmation of Flowcharts in the Field;
9. Preparation of a List of Potential Hazards;
10. Determination of Critical Control Points (CCP);
11. Establishing CCP Critical Limits;
12. CCP Critical Limit Monitoring;
13. Creation of HACCP Documentation and Records;
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 Undang Undang tentang Pangan UU RI No.18 tahun
2012 (Law on Food Law No. 18 of 2012)

Article 86. item 2

Everyone who produces & trades food must meet food
safety & food quality standards.

Article 86. item 3

Fulfillment of food safety standards is carried out
through the application of a food safety & food quality
system.

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Food Chain

5
Hierarchy of Food Safety

FSMS
ISO (Voluntary)
22000

HACCP Law
Regulation
(Mandatory)

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HACCP System
Scientifically based and systematic system
identifying specific hazards and their
control measures to ensure Food safety

In summary, HACCP is applied in the following steps:

1. Pay attention to materials, product processes from start to
finish
2. Identify potential hazards and where they occur
3. Carry out control and monitoring
4. Doing documentation and recording
5. Ensure continuous effective implementation

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DEFINITION OF HACCP
HACCP is a system that
identifies, evaluates and
controls significant hazards
in food safety

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 Definisi
• H a z a r d
• a factor that can cause health disturbances/losses that
affect consumers
• Cr i t ic al Cont rol Poi nt
• The point, stage/procedure at which controls can be
put in place so that food safety hazards can be
prevented, eliminated or reduced to an acceptable
level.
• C r i t i c al Limit
• Criteria to be met for each countermeasure,
associated with each critical control point

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3
History of HACCP
 1959 - The Pillsbury company in the United States together with the US
Army Nautics Research and Development Laboratories, The National
Aeronautics and Space Administration and the US Air Force Space
Laboratory Project Group are developing food for astronauts to eat.
 The full HACCP document was first published by Pillsbury in 1973 and was
later applied to low-acid canned foods.
 In 1993 the FAO WHO Codex Alimentarius Commission adopted the Codex
Guidelines for the Application of the HACCP System.
 In Indonesia :
 1996 issue of Food Law
 SNI 01-4852-1998 "Hazard Analysis System and Critical Control Point Hazard
Analysis Critical Control Point-HACCP.
 SNI CAC/RCP 1-2011 National Recommendations Code of Practice – General
principles of food hygiene

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Food Safety Hierarchy

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PRPs VS HACCP

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 Definition of HACCP
HACCP is a system that identifies, evaluates
and controls significant hazards in food safety

(Codex Alimentarius Commission,1997)

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IMPROVEME
NT OF SAFE
FOOD
SYSTEM

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 Purpose of HACCP
General
Improving public health by preventing or reducing cases of
poisoning and disease through food (“Food born disease”).

Specific
Evaluate how to produce food  any hazard ?
Improve the food production process  critical process
Monitor & evaluate handling, processing, sanitation
Improve self-inspection

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HACCP Components

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 Pre-requiste program (PRP)
How to choose PRP :

PRP has to be :
 In accordance with the needs with respect to food safety
 In accordance with the size and type of process and product
produced
 Can be implemented throughout the production system As a
program that can be applied
 Approved by management (Food Safety Team)

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 Government Policy/Regulation:

 PERMENKES RI NO.1096/MENKES/PER/VI/2011 About

Hygiene sanitation catering services
 KMK No 1204/MENKES/SK/X/2004 regarding Hospital
environmental health requirements
 PP no.36 tahun 2005 on the Implementation Regulation of Law
No. 28 of 2002 on Building
 KMK No. 1087/MENKES/SK/VIII/2010 on occupational health
and safety standards in hospitals

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EXAMPLES OF PREREQUISITE PROGRAM
(PRP)
1. Quality management system
2. Document control
3. Preparedness for emergencies
4. Training
5. Personal hygiene and tidiness practice
6. Medical examination
7. Building structure
8. Employee facilities
9. Zone settings
10.Traffic flow

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EXAMPLES OF PREREQUISITE PROGRAM
(PRP)
11. Protective clothes
12. Utilities management (water, steam,
electricity and gas)
13. Equipment design
14. Maintenance
15. Environmental pathogen monitoring
16. Sanitation
17. Pest control
18. Waste handling
19. Product design and development
20. Label design and application
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EXAMPLES OF PREREQUISITE PROGRAM
(PRP)
21. Design safety analysis
22. Shelf life evaluation
23. R&D trial and consumer test
24. Premium quality and safety
25. Specification
26. Requirements for packaging
27. Goods Receipt Inspection
28. Supplier quality management
29. Operational control
30. Primary production
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EXAMPLES OF PREREQUISITE PROGRAM
(PRP)
31. Hazard control
32. Allergen control
33. Foreign body contamination prevention program
34. Weight control
35. Identification and traceability
36. Equipment calibration
37. Warehousing, handling, storage and
transportation
38. Packaging integrity
39. Food protection
40. Customer service
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EXAMPLES OF PREREQUISITE PROGRAM
(PRP)
41. Consumer education
42. License management and trademark agreement
43. Export/import quality management
44. External manufacturing quality management
45. Acquisition quality management
46. Good laboratory practice
47. Sampling, and pathogen testing
48. Rework control
49. Product containment and release
50. Product recall
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EXAMPLES OF PREREQUISITE PROGRAM
(PRP)

51. Internal quality audit

52. Third party audits
53. Corporate quality audit
54. Corrective and preventive actions

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 H A C C P Plan
1. HACCP TEAM BUILDING
 Top Management Commitment
 Appoint Leaders and Secretaries
 Consists of various disciplines required
 Defining the scope of the HACCP plan
o Defines the types of potential hazards to be included
o Define the part of the food chain to be studied

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 H A C C P Plan
2. Product Description
 Product/product category: name, type, size

 Formulation and Composition: raw materials and additives,

parameters affecting security

 Process: cold packing, hot filling, freeze drying, etc

 Food Safety Characteristics: Biological CCP (Aw, pH, content salt,

preservatives, etc.)

 Target Consumers: General market, age, adults, children, retail, food

services, countries, regions, etc.

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 H A C C P Plan
2. Product Description
 Consumer Use : Ready to eat, heated and consumed, mixed
and consumed, etc
 Label Instructions: Only list BTM containing allergens

 Packaging: aluminum foil, plastic, glass, bowl, can, etc.)

 Shelf Life: (Example: day, and temperature conditions)

 Storage and distribution: room temperature, refrigerator

temperature, humidity, etc.

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 H A C C P Plan
3. Purpose of Use Identifier
 Must be based on the expected usage by the user
 The goal is to list: shelf life, instructions for use, groups of consumers
who use it, and consumer populations that may be sensitive to the
product such as the elderly, sick people, infants, pregnant women,
people with immune problems, etc.

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Examples of Food Safety Characteristics

Types of Food Ingredients Number of Colonies E.Coli

(Total Plate Count)
Animal side dishes 1x105 col/gr Negative

Vegetable side dishes 5x104 col/gr Negative

Vegetable 5x105 col/gr Negative

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 H A C C P Plan
4. Formation of Flow Chart
The flow chart should cover all the stages that the product goes
through and clearly, includes:

 Details of all process activities

 Processes that are carried out by outsiders and those that are
subcontracted

 When all the ingredients enter the process

 When the rework process occurs

 When all materials, products, or waste are released or disposed of

Outputs from processes, such as main products 39
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 H A C C P Plan
5. Verification of Flow Chart
 The flow chart that has been prepared must be verified by
actual condition on the ground
 Verification is done by observing the process flow,
matching the flow chart with the real stages in the field.
 If there are errors, the flow chart must be corrected
immediately.

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 H A C C P Plan
6. Hazard Identification (Principle -1)
Hazard / Risk

When Total of
Biological, Chemical, Physical Bahan
Biologis
Substances mentah
Exceeding the Acceptable Limit,
causing food damage so that it has the
potential to cause health kontaminasi pd Produk
Kimia setengah jadi
problems/diseases

Finished
Physical product

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 H A C C P Plan
6. Hazard Identification (Principle -1)

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 H A C C P Plan
6. Hazard Identification (Principle -1)
Food Type Organism Patogen
Biological Meat or Meat Products Salmonella
S. aureus
E. coli patogenik
L. monocytogenes Virus enteric
Hazard Y. enterocolitica
C. perfringens
Parasit

C. botulinum

Milk and Dairy Products Mycobacterium Brucella Salmonella S. aureus Bacillus sp. Clostridium
L. monocytogenes sp. Virus
E. Coli

Poultry and Poultry Products Salmonella Campylobacte S. aureus

C. perfringens Y. Enterocolitica
L. monocytogenes

Seafood products (fish, V. cholerae L. monocytogenes

shellfish, shrimp) V. parahaemolyticus Parasit
C. botulinum Virus (utama Hepatitis A)

Vegetables Salmonella Shigella Virus Hepatitis A& enteric Parasit

V. cholerae
L. monocytogenes

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 H A C C P Plan
6. Hazard Identification (Principle -1)
Mycotoxin Producing Microbes Contaminated Food
Biological Aflatoksin Aspergillus flavus Corn, peanuts, cottonseed, copra,
Hazard rice, milk, other legumes.

Patulin Penicillium claviforme Apples, grapes, fruits

Okratoksin A Aspergillus ochraceus Wheat, corn, barley, peanuts, grains

Zearalenon Fusarium sp. Corn, barley, sorghum, sesame, corn

oil, starch

Fumonisin Fusarium moniliforme Corn, barley, sorghum, sesame, corn

oil, starch

Botulinin Clostridium botulinum Canned food, meat, fish & sea food,
eggs, vegetables

Asam bongkrek Pseudomonas cocovenenans Bungkil coconut residue, tempeh

demolished

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 H A C C P Plan
6. Hazard Identification (Principle-1)
Group Chemical type Example
Chemical Natuarally Mycotoxins, Scrombotoxin, Fungal Aflatoxin, okratoxin,
Hazard & shellfish toxin, Pyrolizidine zearalenoneHistamineAmato
formed alkaloids, Phytohemagglutinins, xin, palotoxin Paralytic
toxin, diarrhea toxin,
PCBs (polychlorinated biphenyl),
neurotoxin, amnestic toxin
Allergens

Added Agricultural Pesticides, fungicides,

chemicalsMetals/dangerous fertilizers, insecticides,
intentionally objectsAdditives (forbidden or aldrin, antibiotics, growth
or exceeding the limit)Building hormones, fertilizers Pb,
materials & sanitation, Zn, As, Hg, Cyanide Dyes
unintentionall Preservatives (amarant, methanil yellow,
y rhodamine B)Lubricants,
sanitizers, coatingsNitrite,
formalin, borax

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 H A C C P Plan
6. Hazard Identification (Principle-1)

Physical Hazard
1. Stapler
2. Metal
3. Plastic
4. Wood Chips
5. Stone
6. Paper
7. Jewelry

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 H A C C P Plan
6. Hazard Identification (Principle-1)

The hazard analysis should include:

•The probability of occurrence of a hazard and the
degree of its effect on health,
•Qualitative and/or quantitative evaluation of hazards,
•Survival or development of potential hazards of
microorganisms,
•Production or presence of toxins, chemicals or
physical in food,
•Conditions that have a tendency towards danger
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 H A C C P Plan
6. Hazard Identification (Principle-1)

The level of risk (risk) is also grouped into 3 levels based on the effect of
hazards that occur on consumer health / Likelihood of Occurring, namely:
1.Low risk, i.e. if the case can occur less than 3 times within a year.
2.Medium risk, i.e. if the hazard can occur 3-5 times within a year,
3.High risk, i.e. if the danger can occur more than 5 times within a year or
possibly every month.

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 H A C C P Plan
6. Hazard Identification (Principle-1)

Severity is also grouped into 3 levels based on the effects of hazards that occur on
consumer health, namely:
1.Low severity, i.e. if the danger causes minor health problems or can be handled
alone until recovered.
2.Medium severity, i.e. if the danger causes health problems that are severe
enough to require special treatment (hospitalization) in a hospital.
3.High severity, i.e. if the hazard threatens human life or results in death after
consuming the product.

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 H A C C P Plan
6. Hazard Identification (Principle-1)

Acceptable Level
For each identified hazard, the final product acceptance level is
determined

What to consider:
• Regulations and legislation
• Consumer requirements
• Usage plan
• Other relevant data (e.g. literature, expert experience)

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 H A C C P Plan
6. Hazard Identification (Principle-1)
Control Measure
Based on the results of the hazard assessment, selection
is made on:
• control measures
• combination of control measures
 Control measures are taken to:
-Prevent
Until the determined acceptable level
-Eliminate hazards
-Reduce

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 H A C C P Plan
6. Hazard Identification – (Principle 1)
Examples of Control Measure
Hazard Type Example Example of Control Measure
BIological Bacteria Heating, freezing, Ph . setting
Chemical Allergen Allergen cleaning program
Sanitizer Sanitation program
Toxin Supplier quality
lubricant Maintenance program, use of food grade
lubricant
Physical Broken glass Glass policy
Bad Personal Hygiene In-house training on personal hygienefor
employees

Wood Filtering
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 H A C C P Plan
7. Determination of Critical Control Point
(Principle -2)
CRITICAL CONTROL POINT (CCP)

The point, stage or procedure at which controls can be put in place

and food safety hazards can be prevented, eliminated or reduced to an
acceptable level.

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 H A C C P Plan
7. Determination of Critical Control Point (Principle -2)
Decision Tree For Raw Materials
No
Q1 Does
Apakahthebahan
raw material
baku mengandung
contain hazards
bahaya
to an
sampai
unacceptable
tingkat yang tidak
level dapat
? diterima

Yes Not CCP

Bukan CCP

Does
Apakahsubsequent
pengolahan processing/handling (including
/ penanganan selanjutnya Yes
consumer
(termasuk use)
penggunaan
eliminatedithe
konsumen)
hazard or reduce it to a
Q2 safe level?
menghilangkan bahaya atau mengurangi sampai
tingkat aman?

No

CCP

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 H A C C P Plan
7. Determination of Critical Control Point (Principle -2)
Decision Tree for Process Are controls at
this stage
Modification of
Q1 Adakah
Is there tindakan
any control
pengendalian?
measure?
Process or Product Yes
necessary for
security?
Yes No Stages No

Are steps
Apakah tahapan
specifically
dirancang
designed
spesifik
to eliminate
untuk or
menghilangkan
reduce potentialatau
hazards
mengurangi
to an acceptable
bahaya level?
Q2 yang mungkin terjadi sampai tingkatan yang
dapat diterima?

No Yes

Can contamination
Dapatkah kontaminasiwithdengan
identified hazards
bahaya occur
yang
beyond acceptable
diidentifikasi terjadilevels or can this increase to
melebihi
No
Q3 unacceptable
tingkatan yang levels?
dapat diterima atau Not CCP
Bukan CCP
dapatkah ini meningkat sampai tingkatan
yang tidak dapat diterima?

Yes

Apakah
Does thetahapan berikutnya
next step eliminate menghilangkan
the identified
No
bahaya or
hazard yang teridentifikasi
reduce its likelihood of occurrence to CCP
Q4 an
atauacceptable
mengurangilevel?
tingkatan kemungkinan
terjadinya sampai tingkatan yang dapat
diterima?

Yes

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 H A C C P Plan

8.Setting Critical Limit (Principle -3)

 For each CCP a critical limit is determined
 The critical limit is intended to ensure the acceptance
level is not exceeded
 Critical limit must be measurable
 Critical limits based on subjective data must be supported
by: instructions, specifications, and training

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 H A C C P Plan
8. Setting Critical Limit (Principle -3)

Critical Limit Criteria

1. Temperature 7. Preservatives
2. Time concentration
3. Humidity (RH) 8. Salt concentration
4. Aw value 9. Free Chlorine
5. pH value 10. Viscosity
6. Qualitative and 11. Chemical value
Quantitative of 12. Contamination (type &
microbes quantity)

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 H A C C P Plan
9. Setting up a Monitoring System (Principle -4)
•What: Is the object of measurement or monitoring to determine whether the critical
control point is operating within the range of critical limits

Example: Sterilization temperatureHow

•How: Is a method of measurement (quantitative critical limit) physically or chemically.

Requires true/real time and accuracy.

Example: Using a thermometer

•When/Frequency : Range of time or frequency (continuous or paused).

Example: frequency/duration every 15 minutesWho

•Who: The person is competent and trained to do the job. Example: operator

•Where: The place where the monitoring is carried out

Example: Freezer in the Animal Side Warehouse

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 H A C C P Plan
10. Assign Corrective Action (Principle -5)
 Corrective Action is planned for each ccp

 Handling when Critical Limit is Exceeded

 Actions to be taken immediately include:

 Immediate correction and disposition of affected products

 Corrective action to eliminate the cause of the nonconformity

 Recording of actions taken

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 H A C C P Plan
11. Establish Verification Procedure (Principle-6)
Verification is carried out to ensure the HACCP system is
still implemented as planned.

Verification activities may include:

Monitoring record check
Inspection of deviations and actions taken
Visual inspection during production of control measures
Random sampling and analysis
Checking customer or consumer complaints
HACCP internal audit
HACCP plan re-examination

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 H A C C P Plan
12. Defining Documentation (Principle -7)
Documentation in the HACCP system Includes:

 The HACCP system related to the12 steps (For

example: Flowchart, Hazard Analysis, and CCP
Determination)

 Procedures and Work Instructions

 Records of monitoring results, corrective actions, and

verification

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H A C C P Plan

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Hal : 66