This is a series that provides practical perspective for one who wishes to apply the Hazard Analysis Critical Control Point (HACCP) system based on the Codex Alimentarius (CAC/RCP 1-1969, Revision 4, Annex, 2003
Constructing a flow diagram that depicts the entire operation process is the next item on the agenda. The flow diagram should encompass all stages in operation, although, its coverage depend largely on the scope defined for the HACCP system as well as the areas under the control of the facility. A flow diagram in a manufacturing outfit typically commences with the receipt of raw materials, followed by the storage, preparation, processing, packing steps and concluding with delivery. It is pertinent that the flow diagram contains adequate technical data such as storage conditions, time/ temperature requirements and be presented in an accurate sequential manner, including information such as delays between steps and/or entry points for work-in-progress or re-work products. Although it is not specified in the Codex Alimentarius (Codex), it would be helpful and practical to incorporate floor plans indicating movements of raw materials, products, wastes and employees as well as placement of equipments and services.
Developing a well-conceived and accurate process flow diagram which highlights all process steps is critical as it creates the foundation upon which hazard analysis is to be conducted subsequently (in Step 6 of Codex’s 12 Steps to HACCP). By identifying all process steps, potential hazards associated with every step can be carefully analyzed and examined in order to determine their risks and consequently, the significance of the process step in relations to the safety of the product. Overlooking certain process steps can mean ignoring certain potential hazards, which can eventually be detrimental to the overall safety of the product.
It is vital to appoint personnel who are not only familiar with the HACCP requirements but who also have in-depth knowledge and understanding of the food processing system of the facility to perform Step 4. Such personnel can be members of the HACCP team as well as key operations personnel.
The fifth Codex step to the application of HACCP requires the confirmation of the processing operation against the flow diagram for all stages and hours of operations. An on-site verification of the flow diagram should be conducted by the HACCP team to confirm the diagram’s accuracy and completeness. It is common to find minor discrepancies between that which is developed on paper and that which is done on the shop floor. Also, at times, modification to the design of the processing system may be needed. In such instances, they should be highlighted to the HACCP team and key personnel for deliberation. Once the acceptable practices and/or design of the processing system are endorsed, changes to the flow diagram should be made as necessary and all operators involved will need to be informed accordingly. The on-site walk-through also serves as an excellent opportunity to examine any potential for cross contamination associated with the operation.
The finalised flow diagram should be signed and dated by either the HACCP team leader or a designated team member to confirm that it has been verified and that it accurately reflects the processes being addressed in the HACCP Plan.
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By Chew Su Pei
Senior Consultant (CLC, PSB Academy)
References
Reference: Codex Alimentarius CAC/RCP 1-1969, Rev 4, Annex, 2003
(Next topic in this series is “Step 6: List all potential hazards associated with each step, conduct a hazard analysis, and consider any measures to control identified hazards” )
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