Understanding Hazard Analysis Critical Control Points (HACCP)

Introduction to HACCP

The Hazard Analysis Critical Control Points (HACCP) is a systematic and preventive approach to ensuring food safety throughout the supply chain. 

Initially developed by NASA in the 1960s to safeguard food consumed by astronauts, HACCP has evolved to encompass all stages of the food supply chain, including distribution, packaging, preparation, production, and food service establishments, playing a crucial role in preventing foodborne illnesses and ensuring food safety for consumers.

In Malaysia, HACCP was introduced in 1998 and is regulated by the Department of Standards Malaysia (DSM), aligned with international standards such as those of Singapore and the European Union. HACCP in Malaysia categorises food businesses into Low Risk, Medium Risk, and High-Risk categories, and it meets the requirements of ISO 22000:2018.

What Is HACCP Certification?

HACCP certification is a formal recognition that a food business has implemented and maintains a Hazard Analysis Critical Control Points (HACCP) system in accordance with established standards and guidelines. It demonstrates that the business has established effective control measures to identify and manage potential food safety hazards throughout its operations. 

HACCP certification is typically granted by accredited certification bodies or regulatory authorities, following a thorough assessment of the company’s HACCP plan, documentation, and implementation. It provides assurance to consumers, business partners, and regulatory agencies that the certified organisation is committed to upholding high standards of food safety and quality.

Why Is HACCP Important For Companies?

HACCP is important for companies as it ensures food safety, facilitates regulatory compliance, enhances reputation and consumer confidence, improves operational efficiency, and creates opportunities for business growth and partnerships. By implementing HACCP, companies can establish themselves as leaders in food safety and gain a competitive edge in the market.

• Ensuring Food Safety

The primary objective of HACCP is to identify and control potential hazards that could pose risks to food safety. By implementing HACCP principles and practices, companies can systematically analyse their processes, identify critical control points, and establish effective control measures. This proactive approach helps prevent foodborne illnesses and ensures the safety of the food products they produce or handle.

• Regulatory Compliance

Many countries have regulations that require certain sectors of the food industry to implement HACCP systems. Compliance with these regulations is essential for legal and regulatory purposes. Obtaining HACCP certification demonstrates a company’s commitment to meeting these requirements, avoiding penalties, and maintaining a positive relationship with regulatory authorities.

• Reputation And Consumer Confidence

In today’s market, consumers are increasingly concerned about the safety and quality of their food. Implementing HACCP and obtaining certification can significantly enhance a company’s reputation and build consumer trust. HACCP certification is a visible and credible indication that a company follows rigorous food safety practices, instilling confidence in consumers that the products they purchase are safe to consume.

• Operational Efficiency And Cost Savings

HACCP implementation involves a systematic analysis of processes and control measures. This analysis can lead to identifying areas for improvement, optimising resource allocation, and reducing waste. Companies can reduce costs, minimise product losses, and improve overall productivity by enhancing operational efficiency. HACCP helps streamline operations and ensures that resources are allocated effectively to maintain food safety standards.

• Business Opportunities And Partnerships

Many retailers, distributors, and business partners require suppliers to have HACCP certification as a prerequisite for collaboration. Having HACCP certification opens doors to new markets, customers, and business opportunities. It demonstrates a company’s commitment to meeting international food safety standards, which can be a differentiating factor when seeking partnerships or expanding into global markets.

What Are The 7 Principles Of HACCP?

The seven principles of HACCP (Hazard Analysis Critical Control Points) provide a systematic and science-based approach to ensuring food safety. These seven principles provide a comprehensive framework for designing and implementing an effective HACCP system. This allows companies to identify and control food safety hazards, prevent foodborne illnesses, and ensure the production of safe and high-quality food products. These principles are:

1. Hazard Analysis

Identify and assess potential hazards at each food production, processing, and handling stage. This involves understanding biological, chemical, and physical hazards that may be present and evaluating the severity and likelihood of their occurrence.

2. Critical Control Points (CCPs)

Determine the points in the production process where control measures can be applied to prevent, eliminate, or reduce hazards to an acceptable level. These points are critical for food safety and require monitoring to ensure control measures are effective.

3. Critical Limits

Establish specific criteria or limits for each CCP to ensure the control measures effectively prevent or eliminate the identified hazards. These limits may include temperature, time, pH level, or other measurable factors that must be maintained within a safe range.

4. Monitoring Procedures

Develop procedures to monitor and verify that CCPs are under control. Regular monitoring activities are necessary to ensure that critical limits are met consistently, deviations are identified promptly, and appropriate corrective actions can be taken.

5. Corrective Actions

When monitoring indicates that a CCP is not under control, define appropriate actions to be taken. These actions should be predetermined and designed to bring the process back into control and prevent potentially unsafe products from reaching consumers.

6. Verification Procedures

Establish procedures to verify the effectiveness of the HACCP system. This involves periodic reviews, evaluations, and audits to ensure that the system functions as intended and effectively controls hazards.

7. Documentation and Record-Keeping

Maintain accurate and detailed documentation of all aspects of the HACCP system. This includes hazard analysis, CCPs, critical limits, monitoring records, corrective actions, verification procedures, and other relevant information. Proper documentation provides a historical record of the system’s implementation, assists in traceability, and enables review and improvement of the HACCP plan.

How Does The HACCP Certification Process Work?

The HACCP (Hazard Analysis Critical Control Points) certification process involves several key steps. While the precise details may vary depending on the certification body or organisation involved, the general process of obtaining HACCP certification typically involves the following steps:

1. Preparation

The company prepares for HACCP certification by establishing a HACCP system based on the seven principles of HACCP. This involves conducting a hazard analysis, identifying critical control points, determining critical limits, establishing monitoring procedures, developing corrective actions, and setting up verification procedures.

2. Selection Of Certification Body

The company selects a reputable certification body accredited to grant HACCP certification. Choosing a certification body recognised and accepted in the industry and relevant geographical location is essential.

3. Application

The company submits an application for HACCP certification to the chosen certification body. The application typically includes information about the company’s operations, facilities, products, and the implemented HACCP system.

4. Documentation Review

The certification body reviews the company’s HACCP documentation, including the HACCP plan, records, and related procedures. The purpose is to ensure that the documentation meets the HACCP standard or guidelines requirements.

5. Pre-Assessment (Optional)

Some certification bodies may offer a pre-assessment or gap analysis as an optional step. This allows the company to identify any gaps or areas of improvement in its HACCP system before the official certification assessment.

6. On-Site Assessment

The certification body conducts an on-site assessment or audit of the company’s facilities and processes. Trained auditors visit the company’s premises to evaluate the implementation and effectiveness of the HACCP system. They review records, observe operations, interview personnel, and assess compliance with the HACCP requirements.

7. Corrective Actions

If any non-conformities or areas of improvement are identified during the on-site assessment, the company is provided with a report detailing these findings. The company must address these non-conformities and implement corrective actions within a specified timeframe.

8. Certification Decision

Based on the documentation review and the results of the on-site assessment, the certification body makes a certification decision. If the company meets the HACCP standard or guidelines requirements, it is granted HACCP certification. The certification body issues a certificate that specifies the scope of certification, the validity period, and any conditions or limitations.

9. Surveillance Audits

After obtaining HACCP certification, the company is subject to regular surveillance audits by the certification body. These audits verify that the company maintains compliance with the HACCP requirements. The frequency of surveillance audits depends on the certification body and the certification scheme.

10. Recertification

HACCP certification is typically valid for a defined period, often three years. Before the certification expires, the company must undergo a recertification process, which involves a comprehensive reassessment of the HACCP system. Recertification ensures that the company’s food safety practices remain current and effective.

What Are The Fields That Need To Apply For HACCP?

HACCP (Hazard Analysis Critical Control Points) can be applied in various fields and industries where food safety is critical. It’s important to note that while HACCP is commonly associated with the food industry, its principles and methodology can be adapted and applied to other sectors where product safety and quality assurance are critical, such as pharmaceutical manufacturing and cosmetics production. Some of the key fields that commonly implement HACCP include:

Conclusion

In conclusion, achieving HACCP certification is a crucial step for companies in the food industry to permit the security and quality of their products. It requires careful preparation, a thorough understanding of HACCP principles, and implementation of a robust food safety system. While the process may seem daunting, seeking assistance from food safety experts can help navigate the complexities involved.

Fortunately, there are efficient ways to streamline the certification process, such as seeking guidance from experts who can assist in building a tailored HACCP plan. By prioritising food safety and embracing HACCP, companies can safeguard their consumers, comply with regulations, and enhance their reputation in the industry.

Contact us to get your HACCP certification in Malaysia.