HACCP worksheet?

Hi, We are currently formulating a HACCP Plan. The problem is the disagreement of the team on the content of the HACCP worksheet.

Is it necessary to include all hazard  in the HACCP worksheet even those "obviously" handled by a PRP? Thanks for any input.

I believe, though some people with more experience may want to weight in, that all potential hazards that can cause illness or injury should be listed that are within reason for your product and process.  Within reason is obviously subjective however you don't want an auditor to say "Why didn't you consider this hazard." because if you didn't write it down you didn't consider it (unless you have extensive notes from food safety team meetings you can use to show you considered the hazard but it was so insignificant you didn't include it).

Then you can list if it's covered by a PRP the PRP by name or if it's mitigated by a CP or a CCP you can list it in the next box (some hazards may be mitigated by a combination that's why I suggest two boxes)

However the short answer is even a hazard that is mitigated by a PRP should be listed in my opinion.

Thanks for the reply, Merle! Appreciate it much!

Dear vinner,

It may well depend on yr local regulations and any relevant certification standard.

Rgds / Charles.C

PS - added - By inference from yr OP, from a practical POV, you probably need to consider - 

(1) Doing some background reading on HACCP, eg look at Codex, NACMCF, Mortimore&Walllace presentations

(2) Attend a (local) course on HACCP implementation by recognised instructors.

The above should assist an understanding of the preferred order  (eg 7/12 Steps) to apply in the development of a "complete" HACCP Plan.

And understand why Prerequisites are so-named  and their function in the Hazard Analysis "Worksheet".

The original HACCP worksheets contained Sanitation CCPs all over the place. These have now been replaced by PRPs. And the tendency to minimalise total number of CCPs via increasing the scope of PRPs has expanded.

Regarding yr specific OP, unfortunately there is no unique Hazard Analysis layout.

For example some authorities require an explicit risk assessment to be shown on the sheet (eg Likelihood OccurrencexSeverity).Others do not. Others don't care either way.

Some haccp users don't employ Prerequisites at all.

Some haccp users apply the 4Qs method to every process step. Others only apply to (risk assessed) significant hazards. Others don't apply at all.

One FS standard requires a risk assessment of items such as handwashing. Most standards assume it is handled implicitly by Prerequisite programs.

I think you get the point. It's a subjective world as Merle nicely pointed out.

PPS - Yr original question might have been usefully extended/rephrased as - is it necessary to show a detailed risk assessment for hazards which are handled within the Prerequisite Program ? Most haccp presentations will answer No, by definition.

Appendiices HACCP IV D rev Apr09 Rev11.doc   145KB   85 downloads

There are 4 Hazards covered by HACCP:

• Biological
• Chemical
• Physical
• Allergens

In the Hazard analysis and risk assessment document you 

1. Identify the hazard

2. Identify the cause(s) of the hazard

3. Identify the control measures used to control the hazard

4. Risk assess the Hazard ( not the causes) usually using the 3 x 3 matrix ( probability vs Severity) 

5. Identify the pre requisites

6. anything not a PRP goes through whichever decision tree you choose to use and

7. Identify the CCPs

I have recently done a level 6 HACCP course and the whole thing makes much more sense now.

Hope this helps

Level 6?

What HACCP certifying body was overseeing those courses?  The International HACCP Alliance only recognizes Basic and Advanced.

Appendiices HACCP IV D rev Apr09 Rev11.doc

 

There are 4 Hazards covered by HACCP:

• Biological
• Chemical
• Physical
• Allergens

I have also seen radiation listed as a sub category of chemicals (as is allergens)

My understanding of a HACCP program, similar to the response from Ireland above:

     List the hazards.

     Analyze the risk.

     Determine the control measures.

     Document the control measures in a PRP, etc.

If you have a PRP, it means you a controlling a potential hazard.  You don't leave the hazard off your list just because you had a PRP in place before you starting doing the hazard analysis.  Good advice per our food safety consultant:  every potential hazard should have at least one documented control measure (PRP, CCP, etc.), and every PRP should match up with at least one hazard on your list.  Otherwise you have a hazard that is not being controlled (no PRP), or you have a PRP that is not controlling an identified potential hazard.

 Maybe 3 more operational steps to the above (haccp) menus -

(-2)   Define the scope of the Plan. eg where does it start ? End ?

(-1).  Document the safety-related specifications of the input/output items.

(0).   Draw up a confirmed Flow Chart.

It's difficult to meaningfully attempt the hazard analysis without them.

Rgds / Charles.C

Thanks to all! To be clear and specific, let me try to rephrase the question this way. Does the iso 22000:2005 auditors care whether the Hazard analysis worksheet is complete or not? "Complete" means ALL hazards has been identified and listed in the worksheet including those hazards that are handled by a PRP like pest (pest control program). Will it be an "incomplete" hazard analysis worksheet (and a non-conformance) if those kind of hazards (already handled by a prp) were not included in the worksheet? As i understand, pests especially flying and crawling insect would be a hazard for those with open/exposed food processing stage. Thanks.

Thanks to all! To be clear and specific, let me try to rephrase the question this way. Does the iso 22000:2005 auditors care whether the Hazard analysis worksheet is complete or not? "Complete" means ALL hazards has been identified and listed in the worksheet including those hazards that are handled by a PRP like pest (pest control program). Will it be an "incomplete" hazard analysis worksheet (and a non-conformance) if those kind of hazards (already handled by a prp) were not included in the worksheet? As i understand, pests especially flying and crawling insect would be a hazard for those with open/exposed food processing stage. Thanks.

It is unfortunate that you did not mention ISO 22000 earlier to avoid getting unrelated comments.

You should interpret some of the foregoing as applicable to a traditional HACCP Plan, not necessarily the ISO 22000 standard.

The iso 22000 standard spells out what chain of steps are necessary for the implementation of it's HACCP section. Especially with respect to PRP programs and significant hazards.

I suggest you obtain a copy of the iso 22000 standard. And iso 22004. And iso 22002-1.

Rgds / Charles.C

I have also seen radiation listed as a sub category of chemicals (as is allergens)

From what I've seen Radiological hazards only need to be addressed for the SQF Food Safety Standard.

Level 6?

 

What HACCP certifying body was overseeing those courses?  The International HACCP Alliance only recognizes Basic and Advanced.

Level 6 or Level 7 may be done as part of a BSc or MSC course.

I have completed Level 7 Global Food Safety & Global Food Safety Systems

Caz

Ahh. I see.  I have a certain distaste for school... particularly doing homework... and attending classes. 

Thanks for replying though I know at some point I'm going to have to go back to college.