Hazard Analysis and Critical Control Points program (HACCP)

Hazard Analysis and Critical Control Points (HACCP) refers to a system that is established and instituted to monitor all stages of a processing or manufacturing operation to ensure that the final product is not compromised because of microbial contamination . Originally, HACCP was devised for the food processing industry. Now, HACCP has expanded to include the manufacture of pharmaceuticals and other products that could be affected by unwanted growth of microorganisms .

The global scope of the HACCP program reflects the susceptibility of, for example, a food to contamination from different microorganisms at different stages of the processing pathway. The altered storage conditions, physical state and chemistry of the food, and shipping conditions can select for the growth of different microbes. The absence of microbes as a food enters a plant is no guarantee that the food will remain uncontaminated. The monitoring of points along the production pathway that are deemed critical and susceptible to contamination can reveal problems and spur remediation of the problems.

The concept of HACCP arose in 1959 at the Pillsbury Company. At that time, the company was contracted to provide food products for the United States manned space program. A system of stringent quality control was needed, because astronauts would not have access to medical attention in the event of the development of a food poisoning or intoxication event in space. The concept of a controlled series of checks was born. In 1971, at the United States Conference on Food Protection, the principles of HACCP were formally described. The principles and procedures of a HACCP program have since been formalized by the National Advisory Committee on Microbiological Criteria for Foods.

Then, as now, there are three principles to the program. First is the identification of hazards found all the way from the field to the marketplace, and the determination of the urgency of each hazard in terms of remedy. Second is the formulation of steps to control or prevent the occurrence of those hazards that warrant remediation. Last is the establishment of a system to monitor the points in the manufacturing process that have been deemed either critical to product quality or a point at which contamination could occur.

A critical part of a HACCP program is the writing of what are known as standard operating procedures (or SOPs). A SOP documents exactly how a test or monitoring will be conducted, how often it will be conducted, and both how—and to whom—the results of the test or monitoring will be reported. This ensures that the food or other material that is being guarded from contamination will be treated the same way. In this way, if a problem occurs, there is a standard in place, which allows for a frame of reference in which to properly evaluate the problem.

A properly operating HACCP program is not, of course, a guarantee that no problems will occur. However, the chances of microbial contamination will be reduced, because problems will be noted as they develop (for example, the need to clean a piece of equipment or the accumulation of stagnant water in a pipeline), rather than being confronted by a contamination problem with no warning. Knowledge of the types of contamination problems that can arise can help pinpoint the source of a contamination, and so can minimize the time that a production line is shut down.

An important aspect of a HACCP program is that all remediative procedures that are contemplated must be capable of being routinely performed. If a solution is not easily done, the control step is meaningless. An adjunct to a successful HACCP is the industrial concept of Good Manufacturing Practices (abbreviated GMP). Essentially GMP is a series of quality control measures designed to ensure that a process proceeds as planned.

Another important aspect of a HACCP program is the verification that the program is operating properly. This can involve the use of known strains of bacteria to verify that the examination techniques being used to monitor a process do indeed detect the bacteria. Such tests should be performed regularly (daily, weekly, monthly) and the results should be documented.

HACCP programs involving microorganisms typically are revised as more becomes known about the microbe of interest. As further information is learned of, for example, the microbe's habitat, growth conditions, and environmental niches, more monitoring or the use of additional examination techniques may need to be incorporated into the HACCP program.

See also Disinfection and disinfectants; Food safety