Your HACCP system can be substantially improved using by following the requirements of the ISO 22000 standard.ISO 22000 clause 7.2 Prerequisite Programmes states the requirement to establish programmes to assist in controlling the introduction of food safety hazards to the product through the work environment, preventing contamination of the product and limiting food safety hazard levels in the product and product processing environment.
ISO 22000 clause 7.2.3 states that construction and lay-out of buildings/premises, workspace, employee facilities; supplies of utilities, waste disposal, adequate equipment, management of purchased materials, storage and transport, prevention of cross contamination, sanitation, pest control and personnel hygiene should be taken into consideration when establishing prerequisite programmes. ISO 22000 clause 7.3.2 requires a food safety team with multi-disciplinary knowledge and experience in developing and implementing the food safety management system to be appointed. The food safety team are required to carry out a number of preliminary steps in order to carry out the hazard analysis.The first step for the team in implementing an ISO 2000 compliant HACCP system is to describe the product characteristics (Clause 7.3.3) including raw materials, ingredients, product contact materials and end product including its intended use(Clause 7.3.4). Clause 7.3.5.1 Flow diagrams requires the food safety team to construct flow diagram and conduct on site confirmation of the flow diagram. Next the food safety team describe each process step and the existing control measures applied at each step as required by ISO 22000 clause 7.3.5.2. This completes the preliminary information required for hazard analysis.
The food safety team now conduct a hazard analysis to identify all the food safety hazards that are reasonably likely to occur and their acceptable levels (ISO 22000 clause 7.4.2). Clauses 7.4.3 and 7.4.4 prescribe that the food safety team should assess each hazard identified then select control measures to the defined acceptable level. The food safety team need to review each control measure and its effectiveness to decide if the control measure is to be part of the HACCP plan or to be controlled by operational prerequisite programmes. Operational prerequisite programmes must be documented and include the food safety hazard to be controlled, the control measure, the monitoring procedures, corrections and corrective actions to be taken if out of control, the responsibilities and authorities and the records to be completed as defined in ISO 22000 clause 7.5.
The next step of implementing an ISO 22000 compliant system requires the food safety team to establish the HACCP plan.ISO 22000 clause 7.6 uses the same principles of HACCP implementation as CODEX, clause 7.6.2 requires identification of critical control points, clause 7.6.3 requires the food safety team to determine critical limits for critical control point, clause 7.6.4 requires monitoring of critical control points, clause 7.6.5 requires actions when critical limits are exceeded and clause 7.8 requires verification planning.The HACCP plan documents the food safety hazard to be controlled at the critical control point, the control measure, the monitoring procedures, critical limits the records to be used, the corrections and corrective actions to be taken if out of control, and responsibilities and authorities. Clause 8.2 describes the requirement for validation of operational PRP and HACCP plan control measures and combinations.ISO 22000 has further specific documentation requirements are prescribed in clause 4.2 which requires that documents and records required by the food safety management system to be controlled.
Product characteristics, intended use, flow diagrams, process steps and control measures should be updated when the HACCP plan and/or operational prerequisite programmes have been completed as per the requirements of ISO 22000 clause 7.7.After updating the preliminary information the food safety team should then decide if the HACCP plan and/or prerequisite programmes documents need to be amended. When verification results do not indicate conformity ISO 22000 requires the food safety team to review of the conclusions of the hazard analysis, operational PRPs and the HACCP plan as per clause 8.4.2. The last requirement is that the food safety team are to evaluate the food safety management system at planned intervals and then consider the need to review the hazard analysis, operational prerequisite programmes and the HACCP plan as described in ISO 22000 Clause 8.5.2 Updating the food safety management system.
About the Author
I’m commited to helping industries achieve a level of excellence that allows them to meet all the necessary requirements to gain ISO 22000 certification