Hazard Analysis & CCP Calculator Guide Part 2 Using · Hazard Analysis & CCP Calculator Guide Part...

Hazard Analysis & CCP Calculator Guide Part 2 – Using the HACCP Calculator Worksheet

Document Reference HACCP Calculator Guide Part 2 Revision 2 26 February 2009 Owned by: Technical Manager Authorised By: Site Director

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1

Decision Tree

= NOT a CCP

N = Check

= CCP

Pro

bab

ility

Severity

Sig

nific

an

ce

Are

co

ntro

l measu

res in

pla

ce

for th

is h

azard

?

Do

es th

e s

tep

elim

inate

or

red

uce th

e h

azard

to a

n

accep

tab

le le

vel?

Co

uld

co

nta

min

atio

n o

ccu

r at

un

accep

tab

le le

vel o

r incre

ase

to u

naccep

tab

le le

vels

?

Will a

su

bseq

uen

t ste

p e

limin

ate

the h

azard

or re

du

ce it to

an

accep

tab

le le

vel?

Step Number

Step Name Hazard

1 Storage of Ingredient 1

Automatically

inserts from

Process Flow

Chart

worksheet

Automatically

inserts from

Process Flow

Chart



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2

Decision Tree

= NOT a CCP

N = Check

= CCP

Pro

bab

ility

Severity

Sig

nific

an

ce

Are

co

ntro

l measu

res in

pla

ce

for th

is h

azard

?

Do

es th

e s

tep

elim

inate

or

red

uce th

e h

azard

to a

n

accep

tab

le le

vel?

Co

uld

co

nta

min

atio

n o

ccu

r at

un

accep

tab

le le

vel o

r incre

ase

to u

naccep

tab

le le

vels

?

Will a

su

bseq

uen

t ste

p e

limin

ate

the h

azard

or re

du

ce it to

an

accep

tab

le le

vel?

Step Number

Step Name Hazard

1 Storage of Ingredient 1

Growth of Bacteria due to warm ingredient * TOXIN PRODUCER

Contamination with Bacteria due to poor water quality

Contamination with Bacteria due to dirty storage container

Contamination from pests

You can now select a hazard from the

drop down list



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3

Pro

bab

ility

Seve

rity

Significan

ce

Step

Number Step Name Hazards Identified

1 Delivery of Ingredient A Bone 3

Campylobacter spp.

Contamination with Bacteria from pests

Pesticides

Salmonella spp. (S. typhimurium, S. enteriditis)

Bacteria (spore-forming) General

Pest control chemicals

Lubricants

Wood

Clostridium perfringens

Stones

What is the likelihood of the hazard

occurring?

Enter:

1 = Unlikely

2 = Possible

3 = Likely



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4

Pro

bab

ility

Seve

rity

Significan

ce

Step


1 Delivery of Ingredient A Bone 3 3

Campylobacter spp. Contamination with Bacteria from pests Pesticides

Salmonella spp. (S. typhimurium, S. enteriditis)

Bacteria (spore-forming) General

Pest control chemicals

Lubricants

Wood

Clostridium perfringens

Stones

What is the severity of the hazard?

Enter:

1 = Not Severe

2 = Could possibly cause illness

3 = Severe (Could be fatal)



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5

Pro

bab

ility

Seve

rity

Significan

ce

Step


1 Delivery of Ingredient A Bone 3 3 9

Campylobacter spp. 1 3 3

Contamination with Bacteria from pests 2 3 6

Pesticides 1 1 1

Salmonella spp. (S. typhimurium, S. enteriditis) 3 3 9

Bacteria (spore-forming) General 2 2 4

Pest control chemicals 1 1 1

Lubricants 3 3 9

Wood 3 1 3

Clostridium perfringens 3 2 6

Stones 3 3 9

The calculator automatically

highlights hazards that are

significant risk in red

9 = Significant risk progress to next

stages



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6

Pro

bab

ility

Seve

rity

Significan

ce

Step Number

Step Name Hazards Identified Specific Details about the

Hazard

1 Delivery of Ingredient A Bone 3 3 9



Pesticides 1 1 1




Lubricants 3 3 9

Wood 3 1 3


Stones 3 3 9

Enter specific details about the

hazard here

You can also enter a comment as to

how you came to the significance

result



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7

Pro

bab

ility

Seve

rity

Significan

ce

Step


Specific Details about the Hazard

Preventative Measure

1 Delivery of Ingredient A Bone 3 3 9 Fish contains bones Fish is filleted prior to cooking



Pesticides 1 1 1




Lubricants 3 3 9

Wood 3 1 3


Stones 3 3 9

Enter preventative measures that

are in place that help control the

hazard here



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8

Decision Tree

=

NOT a CCP

N =

Check

=

CCP

Pro

bab

ility

Seve

rity

Significan

ce

Q1 Step

Number

Step Name Hazards Identified Specific Details

about the Hazard Preventative

Measure

1 Delivery of Ingredient A

Bone 3 3 9 Fish contains

bones Fish is filleted

prior to cooking



Pesticides 1 1 1

Salmonella spp. 3 3 9



Lubricants 3 3 9

Wood 3 1 3


Stones 3 3 9

Now refer to the decision tree

question 1

Are Control Measures in place for

this hazard?

Decide if Control Measures in place for this

hazard and enter:

Y for Yes

N for No

Do not leave blank

Stop at this point if the cell becomes coloured

The decision tree steps only need

to be considered for significant

hazards



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9

Decision Tree

=

NOT a CCP

N =

Check

=

CCP

Pro

bab

ility

Seve

rity

Significan

ce

Q1 Step

Number



Measure




prior to cooking Y



Pesticides 1 1 1

Salmonella spp. 3 3 9 N



Lubricants 3 3 9

Wood 3 1 3


Stones 3 3 9

When a cell turns amber you need to stop at question 1 and decide if

control is needed at this step for safety

If No – Stop this is not a Critical Control Point

If Yes – you will need to modify this step, the process or the product

If Control Measures are in place for

this hazard then the cell remains

white and you need to progress to

decision tree question 2



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10

Decision Tree

=

NOT a CCP

N =

Check

=

CCP

Pro

bab

ility

Seve

rity

Significan

ce

Q1 Q2 Step

Number



Measure




prior to cooking Y N



Pesticides 1 1 1




Lubricants 3 3 9 Y Y

Wood 3 1 3


Stones 3 3 9

Does the step eliminate or reduce the

hazard to an acceptable level?

Enter:

Y for Yes

N for No

Does the step eliminate or reduce the hazard to an acceptable

level?

Stop at this point if the cell becomes coloured

If not go onto question 3



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11

Decision Tree

=

NOT a CCP

N =

Check

=

CCP

Pro

bab

ility

Seve

rity

Significan

ce

Q1 Q2 Q3

Step Number



Measure




prior to cooking Y N N



Pesticides 1 1 1





Wood 3 1 3


Stones 3 3 9

Q3 Could contamination occur at unacceptable

levels or increase to unacceptable levels?

Enter:

Y for Yes

N for No

Could contamination occur at unacceptable levels or increase to

unacceptable levels?

Do not leave blank

Stop at this point if the cell turns green this is not a Critical Control

Point

If not go onto question 4



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12

Decision Tree

=

NOT a CCP

N =

Check

=

CCP

Pro

bab

ility

Seve

rity

Significan

ce

Q1 Q2 Q3 Q4

Step Number



Measure




prior to cooking Y N Y N



Pesticides 1 1 1





Wood 3 1 3


Stones 3 3 9

Will a subsequent step eliminate or reduce the hazard to an acceptable

level?

Enter Y for Yes or N for No

Do not leave blank

Red cell indicates a Critical Control Point

Green Cell indicates this is not a Critical Control Point

Q4 Will a subsequent step eliminate or reduce

the hazard to an acceptable level?



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13

Decision Tree

=

NOT a CCP

N =

Check

=

CCP

Pro

bab

ility

Severity

Sig

nific

an

ce

Q1

Q2

Q3

Q4

Step Numbe

r Step Name Hazards Identified

Specific Details

about the Hazard


1 Delivery of Ingredient A Bone 3 3 9 Fish Bones Filleted N

Campylobacter spp. 3 3 9 Your input Your input Y N Y N

Contamination with Bacteria from pests 3 3 9 Your input Your input Y N N

Pesticides 3 1 3 Your input Your input

Salmonella spp. ( 1 3 3 Your input Your input

Bacteria (spore-forming) General 2 2 4 Your input Your input

Pest control chemicals 1 1 1 Your input Your input

Lubricants 3 3 9 Your input Your input Y Y

Wood 3 1 3 Your input Your input

Clostridium perfringens 3 2 6 Your input Your input

Stones 3 3 9 Your input Your input Y N Y Y

Your HACCP Calculator should now look like

this with your details in the Specific Details

about the Hazard and Preventative Measure

columns

ALL THE RED CELLS ARE YOUR CRITICAL

CONTROL POINTS



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14

HACCP Plan

Step Numb

er

Step Name

Hazards Identified

Specific Details about

the Hazard


Q1

Q2

Q3

Q4

Critical Limits

Monitoring Procedures

Corrective Action

HACCP Record

1

Delivery of

Ingredient A

Campylobacter spp.

Enter details here

such as risk from

birds

Example covered and screened delivery area

N

1

Delivery of

Ingredient A

Campylobacter spp.

Enter details here

such as risk from

birds


Y N Y N

1

Delivery of

Ingredient A

Contamination with Bacteria

from pests

Enter details here

such as risk from

birds


Y N N

1

Delivery of

Ingredient A

Pesticides Enter

details here


THE INFORMATION FROM THE CALCULATOR IS TRANSFERRED TO

THE HACCP PLAN WORKSHEET



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15

HACCP Plan

Step Number

Step Name

Hazards Identified

Specific Details

about the Hazard


Q1

Q2

Q3

Q4 Critical Limits

Monitoring Procedures

Corrective Action

HACCP Record

1

Delivery of

Ingredient A

Campylobacter

Enter details

here such as risk from birds

Example covered and

screened delivery area

Y Y No Contamination Always load under

cover

Supervision by Warehouse

Manager

Inspect delivery for

contamination. Reject if

contaminated

Good Receipt Record GIREC

1

Delivery of

Ingredient A

Viruses General

Enter specific details about your

hazard

Enter your preventative

measure Y Y

Decide your critical limits and enter

here

Decide your monitoring

procedures and enter here

enter the corrective

action to take if outside of critical limits

Details of where CCP is recorded

11 Cooking

Salmonella spp. (S.

typhimurium, S. enteriditis)

Enter specific details about your

hazard

Enter your preventative

measure Y Y

Decide your critical limits and enter

here

Decide your monitoring

procedures and enter here

enter the corrective

action to take if outside of critical limits

Details of where CCP is recorded

YOU CAN NOW SORT AND FILTER THE ENTIRE TABLE TO BRING THE CRITICAL CONTROL POINTS TO THE TOP

SELECT WHOLE TABLE WITHOUT THE HEADERS AND FILTER BY:

COLUMN I BY CELL COLOUR RED, THEN COLUMN G BY CELL COLOUR RED, THEN COLUMN F BY CELL COLOUR

AMBER, THEN COLUMN I BY CELL COLOUR GREEN THEN COLUMN H BY CELL COLOUR GREEN THEN COLUMN A BY

VALUE SMALLEST TO LARGEST

YOU THEN NEED TO COMPLETE YOUR HACCP PLAN BY ENTERING CRITICAL LIMITS, MONITORING PROCEDURES,

CORRECTIVE ACTIONS AND DETAILS OF THE RECORD ON WHICH THESE ARE CHECKED

THIS INFORMATION IS LINKED INTO HACCP 007 Linked HACCP Plan WORD DOCUMENT THAT IS IN A MORE

PRESENTABLE FORMAT

Hazard Analysis & CCP Calculator Guide Part 2 Using · Hazard Analysis & CCP Calculator Guide Part...

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