1.GMP (Good Manufacturing Practice) is one of the foundations of HACCP, such as China people's * * * and the national standard General Hygienic Standard for Food Enterprises (GB 1488 1-94), and the aquatic industry standard "Quality Management Standard for Aquatic Products Processing" (SC/T 3009-65438+ Workshop and floor, equipment and tools; Hygienic operation (such as working procedures, hazardous substance control, laboratory testing, etc.). ); Sanitation facilities and control, including water use, sewage treatment and equipment cleaning; Equipment and instruments, design and technology; Processing and control (for example, raw material receiving, inspection, production, packaging, storage, transportation, etc. ).
2.SSOP (Hygienic Standard Operating Procedure) is the cornerstone of HACCP plan, which mainly involves eight aspects:
① Safety of treated water;
(2) the condition and cleanliness of the food contact surface;
③ Preventing cross-contamination;
(four) to maintain the sanitary facilities of toilets, hand disinfection rooms and toilets;
⑤ Prevent food doping;
⑥ Proper identification, storage and use of toxic components;
⑦ Control of employees' health status;
⑧ Eliminate pests.
All of these eight aspects have corresponding hygienic standards of GMP regulations.
3. Product identification (coding), traceability and recovery procedures are one of the prerequisites for implementing HACCP system. Product containers, packing boxes and even pallets should have appropriate identification systems to facilitate product traceability and recycling. It is necessary to establish a recovery plan to test whether the plan is as effective as set, and not wait until the crisis comes in the actual recovery process to test whether the recovery plan is effective.
4. Preventive maintenance plans and procedures for equipment.
5. Staff education and training planning procedures. In order to effectively implement the HACCP plan and make the whole company successful, it is most important that all employees, including managers, should understand the HACCP plan and receive education and training from it.
Second, seven tasks to be done in formulating HACCP plan:
1. Conduct hazard analysis, determine relevant hazards, and determine corresponding measures to control relevant hazards;
2. Determine the critical control point (CCP);
3. Determine the critical limit of each critical control point;
4. Develop monitoring procedures;
5. Clear corrective measures;
6. Establish a recording system;
7. Develop verification procedures;
Third, the steps of making HACCP plan:
1, forming HACCP working group.
The members of the working group are composed of representatives of major departments and units related to enterprise quality management, and should include technical experts familiar with production technology and equipment, as well as personnel with knowledge of food processing hygiene management and inspection. Among them, at least the team leader should have received the training of HACCP principle and application knowledge. When necessary, enterprises can also seek the help of external experts in this regard.
2. Collect and master the relevant information needed to make HACCP plan, such as drawings of workshops and ancillary buildings; Equipment layout and characteristics; Production process, such as raw material assembly, the use of ingredients and additives, the stagnation time of products between processes, etc. Technical parameters, especially time, temperature and product residence time; Whether there is the possibility of cross-contamination in the flow direction of products during processing; Isolation between clean area and non-clean area of processing site, or isolation between high-risk area and low-risk area where products are contaminated; Cleaning methods of equipment and tools; Environmental sanitation of the factory; Division of labor and health quality activities; Storage and transportation conditions of products, etc.
3. Describe the product.
It can be described from the following aspects: the composition of the product, such as raw materials, ingredients and additives used in processing the product; The organization and physical and chemical characteristics of the product, such as whether it is solid or liquid, colloid or emulsion, its active water and pH value, etc. Processing methods, such as heating, freezing, drying, pickling, smoking, etc. , you can briefly describe the processing process; Packaging, such as canning, vacuum packaging, air conditioning, etc. Storage and transportation conditions, such as whether low-temperature refrigeration is needed; Shelf life of goods, such as sales period, best edible period, etc.; Consumers of products (such as the general public, infants and the elderly) and methods of eating or using products (such as heating and cooking). ); Quality standards adopted by products, especially hygiene standards of products.
4. Draw the product processing flow chart.
Flowchart is a tool for hazard analysis and identification of critical control points, which can be used by HACCP team to complete the remaining steps of making HACCP plan. Draw a processing flow chart for each product, from the receipt of raw materials to the shipment of the product, as well as all the links related to product processing such as pretreatment, processing, packaging, storage and shipment of the whole product, including the residence time between each working procedure of the product, and describe the additional instructions on product processing technology, technical operation and quality requirements. After the flow chart is drawn, it should be verified by the production site to avoid mistakes and omissions.
5, hazard analysis and determine the corresponding control measures.
(1)HACCP team conducts hazard analysis and determines critical control points (CCP) according to various biological, chemical and physical factors harmful to consumers' health. Hazards related to food safety and hygiene are usually divided into the following three categories:
(1) biological hazards, such as pathogenic bacteria, viruses and parasites;
② Chemical hazards, such as pesticide and veterinary drug residues, illegally used feed additives, industrial chemical pollutants, and various toxic chemical elements, such as lead, arsenic, mercury and cyanide; And toxic substances produced by microbial metabolism, such as staphylococcus aureus enterotoxin, botulinum toxin, aflatoxin, shellfish toxin, etc.
(3) Physical hazards, such as broken glass, metal fragments and other substances that can cause harm to human body.
(2) There are two main sources of harm: raw materials are formed in the process of planting, harvesting and transportation or are polluted by the environment; Formed or contaminated during processing.
(3) Determination of work steps of hazard analysis and corresponding control measures:
(1) find out the potential danger. When conducting hazard analysis, HACCP team should start with the cultivation and breeding of raw materials, analyze each production link one by one along the production process of products, and list the possible biological, chemical and physical hazards in each link, that is, potential hazards.
(2) Determine whether the potential danger is significant. Not all potential hazards should be included in the monitoring scope of HACCP plan, but the hazards that may occur in the potential hazards and need to be monitored through HACCP. Once they occur, they will cause unacceptable health risks to consumers (called major hazards).
To judge whether the potential hazards are significant or not, it is necessary for the maker of HACCP plan of an enterprise to analyze and judge the actual situation of product production of the enterprise, such as the source of raw materials, processing methods, methods and processes. There are significant differences in hazards between different products and different processes, and even the same product will be different due to different specifications, packaging methods and expected uses. For example, if the batter stays at high temperature for too long, it will be beneficial to the growth of pathogens or the production of staphylococcus aureus toxins, so the time control of this process is a significant hazard. However, it is not a significant hazard to frozen cooked shrimp. Another example is pasteurized crab meat. If the product is sold as fresh crab meat, the harm of pathogenic bacteria residue during pasteurization is significant. If it is cooked for consumers, it is not a major hazard. Therefore, when analyzing and judging the significance of harm, we should analyze the specific situation and avoid copying it mechanically.
(4) Determine the preventive measures to control hazards. After determining the major hazard sources, we should choose the corresponding measures to control the hazard sources. Through these preventive measures, we can eliminate or reduce the generation and influence of the hazard sources to an acceptable level. Controlling one danger may require multiple measures, or one measure can control multiple dangers. For example, raw materials can be inspected and screened, and even the place of origin can be inspected and visited; Control the processing time, ambient temperature and the dosage of additives; Heating, freezing, cooking, adding salt, fermentation, food additives, modified atmosphere packaging, etc. All control measures should have clear operation and execution procedures and be recorded in writing to ensure their effective implementation.
6. Identification of Critical Control Points (CCP) After the major hazards are determined, it is necessary to find the critical control points that need to be monitored through the HACCP plan. The critical control point is the production link that specially monitors major hazards. It can be a production process or several processes. It should be noted here that the critical control points should not be confused with other quality control points in the production process. Although they sometimes overlap, they monitor different objects. In addition, the selection of key control points should pay attention to two words to avoid too many points, otherwise it will lose the focus of control. There are many ways to identify critical control points, and HACCP planners can analyze and judge according to their own knowledge and experience. It can also be used (as shown) to help identify key points. The decision tree is an auxiliary tool to help identify key control points. When using this decision tree, HACCP team must rely on its professional knowledge to analyze and judge each production link one by one according to the order of production process by answering the questions raised by the decision tree in turn.
In the above work, we used a hazard analysis worksheet (see table 1), which integrated the above work. After filling out this form, we can start writing the HACCP plan.
7. Prepare HACCP plan: A HACCP plan should at least include the following seven aspects:
(1) Location of key control points.
Indicate the production process or section where the critical control points are located, such as sterilization and cooling process in canned food processing and shelling-meat removal-grading-weighing/packaging process in low-bacteria crab meat processing.
(2) Major risks that need to be controlled.
Indicate the major hazards that need to be controlled at this critical control point, such as the reproduction of pathogenic bacteria, the production of toxins, the excessive use of additives, metal fragments, etc.
(3) Critical limit value (CL).
Critical limit (CL) is the standard that preventive measures taken at critical control points (CCP) must meet or conform to. Critical limit is an observable and measurable index, which can be physical, chemical and biological parameters or a specific state. These indicators such as: temperature, time, pH value, water activity, added amount or salt content, sensory indicators such as appearance or texture. Usually, the appropriate critical limit is not necessarily obvious or easy to obtain, so we need to carry out experiments or collect relevant information from scientific publications, regulatory indicators, experimental research by technical experts and so on to establish the critical limit. In order to avoid the loss caused by deviating from the critical limit, some enterprises often set a stricter limit than the actual critical limit, or called the operating limit (OL). In the production process, the processing personnel can adjust the processing according to the operation limit to avoid losing control and take corrective measures. HACCP team should verify whether these critical limits effectively control the related hazards and keep relevant verification records.
(4) monitoring program.
This is the most important part of HACCP plan, and it should be clear in the monitoring procedure that:
-What is monitored, temperature, time, pH value, moisture or quality certificate of raw material supplier?
-What methods are used for monitoring, manual observation or automatic instrument measurement? The monitoring method should be simple, fast and easy to operate.
-The frequency of monitoring, that is, the number of times of monitoring within a specified time, is it continuous monitoring or intermittent monitoring?
-Who is in charge of monitoring, the quality supervisor or the operator?
(5) Corrective measures
Corrective measures are the corrective measures taken against the deviation of critical limits of critical control points before the hazards appear. HACCP team can determine the corresponding corrective measures for each key control point according to the product characteristics and production process of the enterprise, eliminate the causes of deviation, and restore and maintain the normal control state; It is to eliminate the influence of deviation on product quality; This is to prevent those products whose sanitary quality is affected by deviating from the key limits from causing harm to consumers' health. For example, in the production of canned food, when the temperature rises and falls below the temperature level specified by the critical limit value (CL) during sterilization, if the sterilization pot is CCP point, corrective measures can be taken by extending the sterilization time. When formulating corrective measures, the person responsible for taking corrective measures shall be clearly defined; Specific rectification methods; Handling methods of products affected by deviation from critical limits; Record corrective actions.
(6) Monitoring records
The monitoring of each key control point should form corresponding records, and the monitoring information recorded in these records is evidence to show the controlled state of key points. The planner should stipulate a recording system for each key point, that is, what should be recorded? How to record it? When will it be recorded? Who recorded it? Who will review it? And so on, and design a unified and standardized record chart. As for the specific style of the record chart, each enterprise can decide by itself, but HACCP monitoring records should generally include the following information: header, that is, the name of the record; Enterprise name; Record time; Product identification, that is, product variety, specification, model, production batch number or production line and shift; Data/results of actual observation or measurement; Critical limit; The identity of the recorder, such as signature, seal or work number; Record the identity of the auditor, such as signature, seal or work number; Time for reviewing records, etc. Enterprises should ensure the objectivity and authenticity of HACCP monitoring records in the process of implementing HACCP plan. The review of records shall be conducted by personnel who have received HACCP training or have rich experience in quality management.
(7) Verification measures
It must be verified whether the hazards identified by each key point are effectively controlled. Generally, the specific way to verify the monitoring situation of each key point is to calibrate the monitoring equipment regularly; Conduct targeted sampling inspection and analysis of raw materials, semi-finished products or finished products; Check the monitoring records.
(8) Others
In order to facilitate management and use, each HACCP plan is generally prepared in tabular form for easy reference; The document number should be listed on the first page of the schedule; Name and address of the enterprise; Product description, including product name, packaging, storage, transportation and sales methods, supply targets and eating methods, etc. ; The approver of the plan and the date of approval, etc. As shown in Table 2, the format example of HACCP plan is for your reference. )
Four. Verification of HACCP plan
Whether the implementation of HACCP plan can achieve the expected purpose and effect, enterprises should establish procedures to verify HACCP plan. In addition to verifying the above key points, these verification activities include the following two activities:
1, confirmed. Before the formal implementation of HACCP plan, the effectiveness of HACCP plan should be confirmed. In particular, the raw materials or processes for production have changed; Verify that the data has the opposite result; Critical limit deviation appears repeatedly; Risk control has new means and information; New situations are observed in production; Changes in sales methods and users, etc.
2. review. There are two main ways:
(1) First, regular internal audit; The main contents of internal audit are: checking the accuracy of product description and production flow chart; Check whether the key control points are controlled according to the requirements of HACCP plan; Whether the production process runs within the specified critical limits; Whether the monitoring records are accurate and recorded as required; Whether the monitoring activities are carried out in the place specified in the HACCP plan; Whether the monitoring activities are carried out according to the frequency specified in the HACCP plan; Whether there is rectification when the critical limit deviates; Monitor whether instruments and equipment are calibrated according to the frequency specified in HACCP plan.
(2) Regular inspection and analysis of finished products.
(3) The audit shall be conducted by qualified personnel and recorded accordingly.
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