1-HACCP Manual

Document # MWPL/HACCP/001
Revision # 00
HACCP Manual Issue Date June, 2015
Page # 1 of 34
Title: HACCP System Manual
HACCP System Manual

“Food Safety System”
Document Copy # 01 Issued Status: _____________________
Activity Name/Designation Signature Date
Mr. Muhammad Shahid

Prepared By
HACCP Team Leader
Mr. Raja Faisal Shehzad

Approved By
Chief Executive
Distribution List
 Chief Executive
 Head Office
 Slaughter House
 QA Manager
 Lab Incharge
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Table of Contents
S. No. Contents Page #

0.0 Amendment Sheet 3
1.0 Purpose & Scope 4
2.0 Definitions 5
3.0 Prerequisite Programs 7
3.1 Management Assurance 7
3.2 Food Safety Policy 8
3.3 Sanitation Standard Operating Procedures 9
3.4 Training 10
3.5 Product Recall 12
3.6 Customer Complaints 13
4.0 HACCP Plan Requirements 13
4.1 HACCP Plan Development & Implementation 13
4.1.1 Flow chart of HACCP plan development & implementation 15
4.1.2 Product Specification 16
4.1.3 List of Raw Materials 17
4.2 HACCP Team 17
4.3 Process Flow Diagram 19
4.4 Hazard Analysis & Preventive Measures 20
4.5 Critical Control Points (CCP’s) 23
4.6 Critical Limits 24
4.7 HACCP Plan 25
4.8 Monitoring Procedures 27
4.9 Corrective Actions 28
4.10 Verification Procedures 30
4.11 Documentation & Records Keeping System 31
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0.0 AMENDMENT SHEET

Rev. # Date Page # DCP # Nature of amendment
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1.0 PURPOSE & SCOPE
This manual is based upon the principle that food safety is best ensured
through the identification and control of hazards in production, manufacturing
and handling of food. This manual is developed in accordance of “Hazard
Analysis and Critical Control Point system (HACCP)” which is adopted by the
joint WHO/FAO Codex Alimentarious Commission and or MI-Specifications H-
01 (Requirements of Operational HACCP System), rather than relying on end
product standards alone.
This manual enables to implement a food safety program based upon the
HACCP concepts. The food safety program is to be implemented and reviewed
by Top Management and is subject to periodic audit by a suitably qualified
third party food safety auditor. An internal qualified auditor however will do the
audit of this food safety program after every six months before third party
audit.
This HACCP manual is applicable to all the operations of slaughterhouse from

procurement of livestock, slaughtering of animal, meat processing, packaging,
storage & up to the final dispatch of shipment of carcass which are designed
upon the principles and guidelines of HACCP “Hazard Analysis Critical Control
Point System”. This HACCP manual is intended to comply with the
requirements of Codex Alimentarious Commission and MI-Specifications H-01
(Requirements of Operational HACCP System).
Top management takes the HACCP program as a technique, process & a

management system for the assurance of food safety that identifies, evaluates
and controls hazards to ensure food safety. HACCP is applied throughout the
food chain from primary production operations to final shipment to the
customer. They use it as an insurance against food borne incidents and
diseases.
Top management does not rely on traditional quality control system that
emphasize on end product verification which does not provide a comprehensive
management system and is ineffective in ensuring unvarying product quality.
To achieve the safe products without any hazard for customer satisfaction top
management adopts the HACCP system with strong combination of:
 Sanitation Standard Operating Procedures (SSOP’s)

 Standard Operating Procedures/or Work Instructions
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Organization applies this unified comprehensive and systematic approach to:
 Assess the hazards to products and to decide on the control measures to

limit the risks
 Define the responsibilities of the work force in relation to the control of
hazards
 Improve the efficiency of the production process, reduce wastage and ensure
safe and healthy products
2.0 DEFINITIONS
Following are the terms related to HACCP system & of meat-processing for
personnel clarity so that they clearly understand the effective documentation,
development and implementation of this system:
HACCP System Definitions

Acceptable level The presence of a hazard, which does not pose the
likelihood of causing an unacceptable health risk.
Control To take all necessary actions to ensure and maintain
compliance with criteria established in the HACCP Plan.
Control point Any point in a specific food system at which loss of
control does not lead to an unacceptable health risk.
Critical control A point at which loss of control may result in an
point unacceptable health risk.
Critical Limit A value that separates acceptability from
unacceptability.
Critical limit The maximum or minimum value to which a physical,
biological, or chemical parameter must be controlled at
a critical control point to minimize the risk that the
identified food safety hazards may occur.
CCP Decision Tree A sequence of questions to assist in determining
whether a control point is a CCP.
Criterion A requirement on which a judgment or decision can be
based.
Control Measure Any action or activity that can be used to
prevent/eliminate or reduce a significant hazard.
Corrective Action The actions to be taken when the results of monitoring
the CCP indicate a loss of control.
Deviation Failure to meet a required critical limit for a critical
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control point.
Food Hazard Any biological, chemical, or physical agent that is
reasonably likely to cause illness or injury in the
absence of its control.
Hazard A biological, chemical or physical agent or condition
with the potential to cause harm / adverse health effect.
Hazard A biological, chemical, or physical property that may
cause an unacceptable consumer health risk.
Hazard Analysis The process of collecting and evaluating information on
hazards and conditions leading to their presence to
decide which are significant for food safety and
therefore should be addressed in the HACCP plan.
HACCP A systematic approach to the identification, evaluation,
and control of food safety hazards.
HACCP Plan The written document which is based upon the
principles of HACCP and which delineates the
procedures to be followed.
HACCP System The result of the implementation of the HACCP Plan.
HACCP Team The group of people who are responsible for developing,
implementing and maintaining the HACCP system.
Monitor A planned sequence of observations or measurements of
control parameters to assess whether a CCP is under
control.
Monitoring A planned sequence of observations or measurements of
critical limits designed to produce an accurate record
and intended to ensure that the critical limit maintains
product safety. Continuous monitoring means an
uninterrupted record of data.
Preventive Physical, chemical or other factors which can be used to
Measure control an identified hazard.
Preventive Actions to exclude, destroy, eliminate, or reduce a
measure hazard and prevent recontamination through effective
means.
Prerequisite Procedures, including Good Manufacturing Practices
Programs that address operational conditions providing the
foundation for the HACCP system.
Processing Activities that are directly related to the production of
products.
Processor Any person engaged in commercial, custom or
institutional processing of products.
Organization Organizations providing products or services with the
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food chain from production, preparation, processing,
packaging, storage & distribution until the point of
consumption.
Risk An estimate of the likely occurrence of a hazard.
Shelf Stable A product that is hermetically sealed and when stored
Product at room temperature should not demonstrate any
microbial growth.
Step Any location or stage in food production and/or
manufacture their receipt and/or production,
harvesting, transport, formulation, processing
manufacturing, storage, etc. as identified in the flow
diagram.
Sensitive Any ingredient historically associated with a known
ingredient microbiological hazard that causes or contributes to
production of a potentially hazardous food as defined in
the Food Code.
Severity The seriousness of the effect(s) of a hazard.
Validation That element of verification focused on collecting and
evaluating scientific and technical information to
determine whether the HACCP plan, when properly
implemented, will effectively control the identified food
hazards.
Verification The use of methods, procedures, or tests in addition to
those used in monitoring to determine compliance with
the HACCP plan, and /or whether the HACCP plan
needs modification in order to enhance food safety.
Verification Methods, procedures, and tests used to determine if the
HACCP system in use is in compliance with the HACCP
plan.
3.0 PREREQUISITE PROGRAMS
3.1 Management Assurance
Top management of PFP is fully committed to food safety program and

demonstrates its commitment to the development and continually improvement
of the food safety system by:
 Communicating at all levels in the organization the importance of meeting

customer as well as regulatory and legal requirements of food safety.
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 Establishing the food safety policy and ensuring that it is deployed
effectively at all functions and levels.
 Performing management reviews and ensures that HACCP system

performance is effectively reviewed at relevant levels.
 Ensuring the availability of necessary resources for the fulfillment of food
safety program.
Functions and their interrelationships within the organization including

responsibilities and authorities are defined and communicated in order to
facilitate effective management. The organizational chart describes the
hierarchical structure of the organization. The Job descriptions of individuals
describe the responsibilities and authorities of the personnel. However system
manuals and procedures (first & second level documents) also describe the
responsibilities of personnel in relation to various system requirements. All
newly appointed employee bio-data is maintained through employee
registration form and photocopy of all relevant credentials is also maintained.
Pakistan Food Products maintains internal communication through feedback,

suggestions, and office memos, between various levels and functions regarding
food safety system (HACCP) & its effectiveness. This ensures their active role in
implementing this system through their participation. The food safety policy,
goals, procedures, and records are properly communicated on time to relevant
persons through displays & training sessions to keep them fully aware. For
reference check the following records;
 Organizational Chart MWPL/QR/MGT/001

 Job Description Form MWPL/QR/MGT/002
3.2 Food Safety Policy
Organization has established its policy for food safety program. For this
purpose, Top Management ensures that it:
 Is appropriate to the purpose of the organization

 Includes a commitment to comply with requirements
 Is communicated, understood & implemented throughout the organization
 Is regularly reviewed for continuing suitability
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The food safety policy is the main guiding principle that provides the focus of
food safety to the whole organization. Top Management communicates and
enforces the food safety policy. It is also displayed in Urdu and English at
appropriate locations within the organization. For reference check the food
safety policy – MWPL/QR/HACCP/002
Organization is committed to set, implement & maintain high standards of

personal & operational hygiene to safe guard the health & well being of
customers and staff alike. For sake of this we;
 Purchase only healthy & safe, sound livestock for slaughtering purpose.
 Establish systems & procedures for controlling the receipt, storage,
preparation, slaughtering, packaging & transportation of the final product
to the customer.
 Provide adequate facilities, equipment & staff to ensure that the
slaughtering facilities are maintained in a hygienic condition at all time &
the food that we supply will always be safe & in good condition.
 All food workers will be trained in good hygiene practices & they will be
made aware of their responsibility to ensure that all their tasks are
performed in a hygienic manner.
Top management will;
 Always purchase healthy livestock.

 Does strict screening of animals at receiving & ante-mortem.
 Does regular postmortem of slaughtered animals.
 Does continuous training of employees regarding hygiene standards.
3.3 Sanitation Standard Operating Procedures
The regulatory requirement for Sanitation Standard Operating Procedures

(SSOP’s) is used as a prerequisite to HACCP. Top management adopts
effectively a sanitation control system within the slaughterhouse, which is in
accordance to the requirements of Moody International H-01 (Requirements of
operational HACCP System). Top management has developed and implemented
sanitation standard operating procedures successfully that addresses
sanitation conditions and practices before, during and after processing of meat.
These SSOP’s are designed to cover the following requirements:
 Safety of water.
 Condition and cleanliness of food contact surfaces.
 Prevention of cross contamination.
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 Maintenance of hand washing, hand sanitizing and toilet facilities.
 Protection of food, food packaging material & food contact surfaces from
adulteration.
 Proper labeling, storage and use of toxic compounds.
 Control of employee health conditions.
 Exclusion of pests.
 Construction & layout.

 Waste control.
Top management is responsible:
 For the implementation and control of these sanitation requirements.

 For monitoring the conditions and practices during slaughtering with
sufficient frequency and commitment to ensure the conformance with those
conditions and practices specified within the standards, which are
appropriate both to the slaughterhouse and to the meat being processed.
 Takes corrective actions to correct in a timely manner those conditions &
practices that are not meeting sanitation requirements by providing
sufficient resources.
Records related to these requirements are maintained within slaughterhouse in

accordance with the procedure “Control of Documents & Records”.
Sanitation standard operating procedure (SSOP) controls are not included

in the HACCP plan as to the extent that these requirements are implemented in
accordance to the SSOP’s. Therefore we do not include sanitation controls as
part of HACCP plan.
3.4 Training
Organization has developed & implements a documented training procedure for

all employees related to food safety & ensures that the HACCP plan is
implemented effectively. HACCP Team Leader is responsible to:
 Provide training for management and Incharge (s) in pertinent food safety
matters, food safety leadership, coaching, and employee empowerment to
take action at any time to prevent a problem.
 Provide training for new employees in pertinent food safety concerns.
 Communicate the food safety program to all employees in training sessions.
 Maintain a written training program.
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 Maintain records of training that include date, department, content, and
attendance.
 Train those employees who are not literate.
 Provide additional training as necessary to ensure current knowledge of
equipment and process technology.
Training and continuing education for all employees are the most important
parts of our HACCP-based quality management. Employees are the individuals
who carry out the policies, procedures, and standards of the food production
facility. Therefore the HACCP Team Leader gives them information about
hazards and their control so that they understand the need for performing
their jobs in a designated manner. They are also given instruction for
expectations of good personal hygiene and proper methods of hand washing
while working in food preparation.
HACCP Team Leader is responsible to train all employees in the procedures

and standards that relate directly to their specific jobs as well as to those
policies that affect food safety in general (e.g., personal hygiene). All new
employees are given orientation training as soon as they are hired. No one is
asked to do a task until he has been trained and can accept the responsibility
for doing the task with zero defects. All new employees are well aware about
the policies, procedures, and standards of the organization. These are reviewed
during on job training. Procedures that are critically important to HACCP
production standards are emphasized in detail. Training meetings use a variety
of educational approaches that may include but not limited to these:
 Handouts
 Demonstrations of proper procedures
 Lectures using slides or overheads
 Guest speakers
Employees are tested on the material and coached in the use of proper
procedures for handling food in order to assure the production of safe food
products. A critical element of control is to enforce policies, procedures, and
standards. Four stages for helping employees to improve their performance are
as follows:
 The employee is given verbal counseling.

 The employee is given verbal feedback.
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 The employee is given written feedback and two to three day suspension to
reinforce the importance of change.
 The employee is released from employment if no improvement is noted.
Records are kept of employee participation in training activities and used to

monitor employee development. Top management knows that the employee
training is an investment in an operation's future. The more knowledgeable
employees become the more of an asset they are to the business. That’s why
they emphasis on the need of training.
3.5 Product Recall/Withdrawal
Organization has a system in place to effectively manage incidents and enable

the effective withdrawal and recall of products. Chief Executive has established
a product recall/withdrawal team. The core members of this team are;
 Chief Executive Mobile: 92

 GM Production Mobile: 92
 QA Manager Mobile: 92
 Lab Incharge Mobile: 92
 Slaughtering Incharge Mobile: 92
 Shift Supervisor Mobile: 92
 Airport Incharge Mobile: 92
Product Recall/Withdrawal Team is committed to manage effectively all

incidents and potential emergency situations that impact food safety, legality or
quality and have effectively in place product recall/withdrawal procedure.
Organization develops a standard operating procedure for the product
recall/withdrawal and identifies all lots of finished products. Documentation of
finished product/or lot bears a card for identification and traceability which
represents the:
 Description of Product
 Slaughtering date
 Expiry date
 Company Details with address and contact numbers.
If during processing of meat any deficiency is found and there is requirement

for its recall/withdrawal in case of seriousness, the HACCP Team Leader will
order for the product to be destroyed or the actions are taken in accordance
with the procedure of nonconformance and corrective and preventive actions.
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Organization has a system in place to report incidents and potential emergency
situations.
This includes consideration of contingency plans, and incidents that include:
 Delay or cancelation of flight.
 Disruption to key services such as fuel, energy, transport (chilling), staff
availability and communications
 Events such as fire, flood or any natural disaster
Product Recall/Withdrawal Team in the event when products which have been
released from the site are affected by an incident gives considerations to the
need to withdraw or recall of products.
In case of these situations, QA Manager works according to the instructions of
Chief Executive, and intimates all concerned about the situation/seriousness
of the event including the client in a timely manner (within three working days
of the decision to issue a recall).
Product Recall/Withdrawal Team prepares a plan to handle the logistics of
product traceability, recover or disposal of affected product and stock
reconciliation according to the instructions of the Chief Executive.
3.6 Customer Complaints
Organization develops a customer complaint file and handles customer

complaints in accordance of corrective & preventive action procedure.
Organization uses the customer complaints as a tool for verification of the
effectiveness of HACCP Plan and strictly enforces the employees to work on this
procedure. All customer complaints received are directed to Chief Executive.
QA Manager fills out a customer complaint form and investigates the cause of
the complaint. Action is taken to correct the cause of the complaint if it is a
legitimate complaint. If any action is taken because of a complaint it is
recorded on the customer complaint form. All of the customer complaint forms
are kept in the file.
4.0 HACCP PLAN REQUIREMENTS

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4.1 HACCP Plan Development & Implementation
To ensure product quality and safety, HACCP system provides a systematic
and preventive approach to the control of raw materials, processes, the
processing environment, packaging and the distribution system. Hence the top
management establishes, develops and designs the HACCP system to
determine potential problems, establish process specifications and ways in
which hazards are controlled.
HACCP system puts controls in place at each point in the slaughtering system
where safety problems could occur from biological, chemical, or physical
hazards. To start a HACCP system, top management writes a HACCP plan.
In the abattoir, top management implements HACCP plan to meat processing
in five preparatory steps and seven HACCP principles in the following logic
sequence:
 Assemble the HACCP team.

 Determine what training is needed for staff including employees,
supervisors and quality control people so all understand what HACCP
means to the abattoir and to them.
 Describe the Product, its intended use & distribution.
 Construct a detailed Flow Diagram of the Process & its on-site verification.
 List all potential hazards associated with each step, conduct a hazard
analysis and consider any control measure to control hazards (Principle 1).
 Determine Critical Control Points (Principle 2).
 Establish Critical Limits for each Critical Control Point (Principle 3).
 Establish a monitoring system for each Critical Control Point (Principle 4).
 Establish corrective actions for CCP deviations that may occur (Principle 5).
 Establish Verification Procedures (Principle 6).
 Establish Record Keeping & Documentation (Principle 7).
HACCP plan is a written document which is based upon the principal activities
of HACCP system and which delineates the procedures to be followed to assure
the control of a specific process or procedure.
For detail check “HACCP Plan – MWPL/QR/HACCP/010”.

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Management Commitment & Understanding

1
4.1.1 Flow chart of logically HACCP plan development & implementation

Assemble HACCP Team
2
Describe product & identify intended use

3
Construct flow diagram

4
On site verification of flow diagram

5
Identify hazards & describe preventive

measures
6
Identify critical control points

7
Establish critical limits for each step

8
Establish a monitoring system for each CCP

9
Establish corrective actions for deviation

that may occurs
10
Establish verification procedures

11
Establish record keeping & documentation

12
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4.1.2 Product Specification
HACCP Team describes the product as under:
Live animals;
 Sheep
 Goat
1 Raw Material?
 Cow
 Buffalo
 Camel
 Mutton (Carcass, Liver, Kidneys, Heart).
2 Product Name?
 Beef (Carcass, Retail Cuts and Liver).
 For further processing / or for cooked meat items
3 How is it to be used?
in home or food service meals.
 Cotton cloth for carcass
4 The type of Packaging?
 Thermo pore only for liver & heart
Length of Shelf Life?  Keep chilled
5
At what Temperature?  10 days at 0 °C after slaughtering
A. Where will it be sold? A. 1) International Level (Importers around the
world).
6 B. 1) General Population.
B. Consumer? C. 1) For further processing or for cooked meat
C. Intended uses? items in home or food service meals.
 Product Description.
7 Labeling Instructions?  Slaughtering date.
 Expiry date.
8 How is the product  Chilled - keep at 0 °C
distributed?  Chilled distribution in chiller van at 0 °C
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Is special distribution
control needed?
Who is the consumer?  Human Beings above the age of 1 year
9 How will the consumer  For further processing or for cooked meat items in
use the product? home or for food service meals.
Specific method of use for  Not to be used/consumed after the expiry of shelf
10
purpose of safety? life.
4.1.3 List of Raw Materials
HACCP Team prepares a list of ingredients and raw materials for each
process/product as under:
Process Product Raw Material Packing Material Others

Mutton
 Carcass Live Animals
 Liver  Sheep
 Kidneys  Goat
 Heart  Cotton cloth  Water
Slaughtering
 Thermo pore  Marking Ink
Beef Live Animals
 Carcass  Cow
 Retail cuts  Buffalo
 Liver  Camel
4.2 HACCP Team
As the first task in developing a HACCP plan is to assemble a HACCP team.

Top management has assembled a group of individuals in the form of a HACCP
Team that have a specific knowledge and expertise appropriate to the raw
material, slaughtering processes, packaging, storage & transportation.
The team is a multi disciplinary and includes individuals from different areas
like engineering, production, sanitation, quality control etc., as well as
employees directly involved in daily processing activities. It is the team
responsibility to develop the HACCP plan and is also responsible to:
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 Conduct a hazard analysis.
 Identify potential hazards.
 Assign levels of severity and risk (likelihood of occurrence).
 Identify critical control points and recommend control measures, critical
limits and procedures for monitoring and verification.
 Recommend appropriate corrective actions when deviations occur.
 Recommend or conduct investigations and/or research related to the
HACCP plan (if information is not available).
 Validate the HACCP plan.
HACCP team that writes the HACCP plan has understanding of basic things
about the establishment:
 The technology and equipment used in the meat processing.

 The practical aspects of meat operations.
 The flow of the process in the abattoir.
HACCP team defines the boundaries of the HACCP Plan, both from a starting
and finishing perspective, and from an inclusions perspective (HACCP Plan
includes quality aspects as defined by the finished product specification, or is
it restricted to food safety-biological, chemical, physical Hazards). While
including other requirements in overall documentation, the priority of HACCP
program is food safety.
The HACCP team leader is the person with primary responsibility for Quality
control and also Incharge of the HACCP Team. HACCP Team consists of the
HACCP Team Leader and additional HACCP Team Members. . For details check
the format of HACCP Team – PFP/QR/HACCP/001
HACCP Team is responsible to follow the four-step quality assurance cycle. In

which they:
 Plan the meat processing operations, how it can be done safely.

 Organize and learn to do each production step and any related tasks
correctly.
 Operate and do tasks according to the procedures and standards of this
manual & immediately check that they meet necessary standards at each
production step.
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 Measure and evaluate what they have done and make suggestions to
management as how to improve tasks and steps with a higher degree of
quality assurance.
If a person does not know how to safely do a task in meat processing, he will
stop his work, ask and learn how to perform it and then return to his job. It is
the responsibility of the team leader to train the employees in accordance with
the procedure “Human Resource Management”.
It is the responsibility of the employees to monitor their own work. In case of a
mistake, they will take any necessary action immediately to assure the
production of safe food. In case of potentially hazardous meat handling
practices, potentially hazardous conditions, or potentially hazardous meat,
they are responsible to stop the working and report to the team leader
immediately. Actions are taken in accordance with the procedure Corrective &
Preventive Actions to resolve the problems. Top Management is also notified as
soon as possible if the situation is not corrected and there is still a hazard. It is
the responsibility of the HACCP team leader to maintain policies and
procedures for employees to follow these in order to assure the production
and/or sale of safe meat products of designated quality. He operates HACCP
quality system in a manner that makes a complete food safety assurance & the
customers receive optimum nourishment, never ill from food, or injured by a
foreign object. For reference check the HACCP Team – PFP/QR/HACCP/001
4.3 Process Flow Diagram
HACCP Team of PFP has constructed a process flow diagram that identifies all
the steps used to prepare the product from receiving up to final shipment. This
flow chart is simple, understandable and complete from the beginning of the
process to the end. HACCP team ensures and verifies the flow chart by walking
through the abattoir to make sure that the steps listed on the diagram describe
what really occurs in producing the product. The flow chart represents the
slaughter process in detail that separates variety meats and final carcass
fabrication. The purpose of this diagram is to find any place in the abattoir
where hazards could occur. - PFP/QR/HACCP/004
Department Activity Final Product Byproduct CCP #
Purchase  Procurement of,  Carcass
1. Livestock
2. Packing Material
3. Marking Ink
Quality Control  Arrival/Receiving Inspection
Storage  Livestock in Lairage
 Packing Material in store
 Marking Ink in store
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Quality Control  Ante-mortem Inspection
Processing  Slaughtering  Blood
 Bleeding (Hanging-10 Minutes rest)
 Head & feet Separation  Head
 Feet
 De- hiding  Hide
 Evisceration  Lungs
 Heart
 Intestine
 Liver
 Kidneys
 Stomach
Quality Control  Postmortem Inspection CCP # 1
Processing  Carcass Trimming
 Carcass Washing
 Carcass Drying
Packing  Marking & Packing
 Storage CCP # 2
 Transportation
4.4 Hazard Analysis & Preventive Measures
A hazard analysis is the identification of any hazardous biological, chemical, or

physical properties in raw materials and processing steps, and an assessment
of their likely occurrence and potential to cause food to be unsafe for
consumption. In a HACCP system, it is the responsibility of the HACCP team to
identify and assess hazards for their risk factors. They are trained and aware
about hazards that have the potential to cause harm to:
 The Product -(Quality Aspect)

 The Consumers -(Safety Aspect)
 The presentation of the product -(Commercial Aspect)
Hazard analysis is specific to our abattoir and methods in meat processing,

however hazards vary greatly from one establishment to another. This is due to
differences in:
 Sources of raw material.

 Meat processing.
 Processing equipment.
 Processing methods.
 Duration of the processes and storage.
 Employee experiences, knowledge, and attitudes.
HACCP Team identifies hazards into following categories:

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A. Biological Hazards -Including presence of pathogens, parasites etc.
B. Chemical Hazards -Including presence of either naturally occurring
chemicals such as Mycotoxins or added chemicals such as industrial
chemicals.
C. Physical Hazards -Including metal instruments, glass fixtures, plastics, etc.
Hazard analysis is a basic procedural step required in the development of the

HACCP plan. HACCP team is responsible for the performance of hazard
analysis. The hazard analysis is performed on the product as it relates to its
final form. Each step of the process is analyzed to identify any hazards that
affect the final product. Then the hazard is placed at the points on the flow
chart where it can be controlled. HACCP team does assessment for each
control point identified on the flow chart, whether hazards relating to food
safety, wholesomeness, or associated with that particular step. It is essential to
distinguish between hazards and risks. Hazards are qualitative whereas risks
are quantitative and thus indicate the likelihood of a problem occurring.
HACCP team is trained in this respect and ranks the hazards as:
A High Risk
B Medium Risk
C Low Risk
The degree of this concern is ranked on the control strategy of the HACCP
team. HACCP team is responsible to do:
 Continually analyze the operations, processes to find new and recurring

hazards through food safety audits, environmental monitoring, and self-
inspections to identify jobs and processes that have hazards and could lead
to food borne illness.
 Maintain appropriate equipment programs to cover the calibration, use,
cleaning, maintenance, and eventual replacement of equipment.
 Maintain an up-to-date cleaning and sanitation schedule for all facility
areas and equipment with specified employee assignments.
 Clean and sanitize utensils and equipment so as to protect against
contamination of food, food contact surfaces, or food packaging materials.
 Follow a written cleaning and sanitation program for all equipment and
premises (production, packaging and storage areas) that includes:
a) The responsible person.
b) The frequency of the activity.
c) The procedures for cleaning and sanitizing.
d) The chemicals and concentrations used.
e) The type and frequency of inspection to verify the effectiveness of the
program.
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 Identify equipment and utensils, identify areas on the equipment requiring
special attention and follow method of cleaning, sanitizing, and rinsing.
 Use chemicals in accordance with the manufacturer's instructions.
 Carry out sanitation program in a manner that does not contaminate food
or packaging materials during or following cleaning and sanitizing (e.g.,
aerosols, and chemical residues).
 Monitors the effectiveness of the sanitation program and verify it by pre-
operational inspections of premises and equipment or, where appropriate,
by microbiological sampling.
 Adjust the sanitation program accordingly.
 Educate employees to create awareness about food safety and HACCP plan.
Normally the sources of hazards are:

 Raw Materials: -that contains biological, chemical and physical
contaminants.
 Processes: -that designed to inactivate contaminants that create hazards
when fail.
 Mishandling: -of materials or products by the food handler.
HACCP Team is responsible to work on SSOP’s & operational procedures to

assure the realization of these sources. Top management realizes the
importance of these procedures to effectively implement the HACCP program.
HACCP Team has developed a written hazard analysis to determine the food
hazards that are reasonably likely to occur. They identify the control measures
with the application of those the hazards are controlled. The written hazard
analysis consists of:
 Identification of food hazards.

 An evaluation of each food hazard identified.
 Identification of the control measures.
 Review of the current process.
 Identification of critical control points.
HACCP Team during the hazard analysis includes the food hazards, which are
introduced within or outside the abattoir. During evaluating the food hazards,
which are likely to occur, the HACCP team gives consideration to the following:
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 Microbiological contamination.
 Parasites.
 Chemical contamination.
 Unlawful pesticides residues.
 Natural toxins.
 Presence of undeclared ingredients.
 Physical hazards.
HACCP team evaluates the following to determine the potential effect of each on
the safety of the finished food:
 The raw material & ingredients.
 The processing procedures.
 The packaging.
 The storage and intended use.
 The abattoir & equipment function and design.
 The abattoir sanitation.
 Employee’s hygiene.
For detail check “Hazard Analysis- PFP/QR/HACCP/007”.

4.5 Critical Control Points (CCPs)
In developing HACCP plan, HACCP team has identified biological, chemical and
physical hazards in the raw materials and ingredients used and in the steps of
slaughtering processes. They also identified preventive measures for each
hazard identified and further identify the points in the process at which the
preventive measures are applied to prevent, eliminate, or reduce the hazard to
an acceptable level. They used the CCP decision tree to assess each step in the
process to determine whether it is a critical control point or not. HACCP team
takes the following steps in identifying critical control points:
 Use CCP decision tree to separate CCP’s from other controls such as
SSOP’s, or other operating procedures.
 Use CCP decision tree in methodically and uses simple, descriptive and
familiar wording.
 Apply CCP decision tree at each step in the process where a hazard is
identified.
 Determine whether a process step is a CCP, is a basic exercise of answering
four questions.
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In CCP determination, HACCP team uses the form and the decision tree in six
steps as follows:
 In Column 1 of the Critical Control Point Determination Form, write in each

step in the process where a hazard is identified.
 In Column 2, write in the identified hazard(s), indicating whether it is
biological, chemical or physical. Then take the information from Hazard
Identification/ Preventive Measures form and answer the following
questions for each identified hazard.
 Question #1 – Do preventive measures exist for the identified hazard? {Note:
From a regulatory standpoint, no further action is necessary if the hazard is
not reasonably likely to occur.} If the answer is yes, write YES and proceed
to the next question. If the answer is no, ask the question “Is control at this
step necessary for safety?” If control is not necessary at this step in the
process, this process step is not a CCP. Write NO in Column 3 and write
how and where this hazard will be controlled. Proceed to the next process
step and identified hazard that entered in Columns 1 and 2. If control is
necessary, in Column 3 explain how the step, process or product will be
modified to ensure safety. Once the step, process, or product has been
modified, return to Question #1.
 Question #2 – Does this step eliminates or reduces the likely occurrence of
the hazard(s) to an acceptable level? If the answer is yes, write YES in
Column 4 and identify the step as a CCP in Column 7. If the answer is no,
write NO in Column 4 and proceed to the next question.
 Question #3 – Could contamination with identified hazard(s) occur in excess
of acceptable levels or could these increases to unacceptable levels? If the
answer is yes, write YES in Column 5 and proceed to the next question. If
the answer is no, write NO in Column 5, indicating that the step is not a
CCP. Then proceed to the next process step and hazard.
 Question #4 – Will a subsequent step eliminates identified hazard(s) or
reduces the likely occurrence to an acceptable level? If the answer is yes,
write YES in Column 6, indicating that the step is not a CCP. Then write
down which processing step that occurs later will reduce the hazard to
acceptable levels. Then proceed to the next process step and hazard. If the
answer is no, write NO in Column 6 and identify the step as a CCP in
Column 7.
For detail check

CCP Decision Tree -PFP/QR/HACCP/008 and
CCP Determination - PFP/QR/HACCP/009
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4.6 Critical Limits
The critical limit is the maximum or minimum value to which a physical,

biological, or chemical hazard are controlled at a critical control point to
prevent, eliminate, or reduce to an acceptable level the occurrence of identified
food safety hazard. Critical limits are expressed as numbers or specific
parameters based on visual observation, such as:
 Time
 Cooling/Temperature
 Humidity
 Water activity
 pH
 Salt concentration
 Chlorine level etc.,
Many critical limits for identified CCP’s have already been established. These
limits are finding out in sources such as:
 Regulatory requirements
 Scientific literature
 Experimental studies and
 Through consultation with experts
The critical limits are based on sound scientific data & assure that the result
produces a safe/unadulterated product. Following are main steps to establish
critical limits;
 For each identified CCP, determine if there is a regulatory critical limit set
for ensuring food safety. If so, write that critical limit--or an alternative one
if the scientific basis exists to show the value is adequate to ensure food
safety—into the critical limit column of the form.
 If there are no regulatory critical limits for a CCP, then establish critical
limits for the CCP that are adequate to maintain control and prevent a food
safety hazard. That is the responsibility of HACCP Team. Once you have
identified critical limits, enter them into the critical limit column of the
form.
 HACCP Team also files, for future reference, any documentation such as
letters from outside experts, processing authorities, or scientific reports
supporting the critical limits identified. This documentation helps to
validate that the limits have been properly established. In addition, keep on
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file any test results that show early experience in implementing the HACCP
plan, to demonstrate that HACCP Team implement what is written and
make it work.
4.7 HACCP Plan
HACCP team develops and implements a written HACCP plan whenever a

hazard analysis reveals that food hazards are reasonably likely to occur during
processing as described in hazard analysis. It is the responsibility of the
HACCP team to develop HACCP plan as they are trained in the HACCP system
documentation and implementation. During HACCP plan development, the
HACCP team keeps in mind the following, as the plan is specific to:
 Each location where product is processed
 Each type of product to be processed
The contents of HACCP plan are:
 List all food hazards.
 List the critical control points for each of the identified food hazards.
 List the critical limits.
 List the procedures for monitoring critical limits.
 Corrective actions in response to deviation from critical limits at CCP’s.

 List the validation and verification procedures.
 List records related to HACCP plan.
Sanitation controls may be included in the HACCP plan but however to the
extent that these are monitored in accordance with the sanitation manual
“SSOP’s Manual”, hence these are not include in the HACCP plan.
In the development and implementation of HACCP system the HACCP team is
responsible to determine the preventive measures. Preventive measures are
defined as any action that will inhibit the introduction of hazards into the
product. It is the responsibility of HACCP team to determine preventive
measure for the identified hazards. Preventive measures include the following:
 Supplier certification of products (Purchase procedure)
 Purchasing specifications (Purchase procedure)
 Machines/equipment maintenance (Machine Maintenance Procedure)
 Training programs for employees (Human Resource Procedure)
 Proper time, humidity and temperature control (Inspection & Testing
Procedure)
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 Production scheduling (Process Control Procedure)
 Adherence to operational procedures or practices
 Machine/Equipment sanitation and maintenance
 Scale calibration (Calibration Procedure)
 Certificate of chemicals
 Proper packing
 Supervisory checks
 Inventory control
For each hazard listed in critical control points, the HACCP team lists the
preventive measures that employ to reduce the possibility of that particular
hazard of occurring.
In order for a control point to be critical, HACCP team is responsible to monitor
and document the control of hazard(s) at that control point. Types of critical
control points may include, but are not limited to these:
 Receiving
 Cleaning
 Packaging
 Storing
 Shipping/transport
HACCP Team is responsible to evaluate compliance with regulatory

requirements, and if necessary, to correct any defects, deviations, or
deficiencies that may be found. Identify on the flow chart the steps that have
been deemed critical control points. A critical limit is defined as an established
point, which must not be exceeded if a hazard is to be controlled at a CCP.
There may be more than one critical limit for a CCP. If any one of those limits
is out of tolerance, the process will be out of control and a potential hazard or
unacceptable risk can exist. The critical limit is used to signal the fact that a
potential hazard/problem exists at a particular critical control point. At this
point, the HACCP team determines the possible solutions and decides which
solution(s) will correct the hazard/problem.
It is important to establish reasonable critical limits that will ensure control of
the potential hazard. The HACCP team sets these limits that are more stringent
than regulatory limits or product-purchasing specifications to ensure that
product are found acceptable. Monitoring is the scheduled testing and/or
observations recorded by the HACCP team to report the findings at each CCP.
Monitoring results are documented. Failure to exercise control of a critical
control point is a critical deficiency in the program.
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Because of the potentially serious consequences of a critical deficiency, HACCP
team prepares effective monitoring procedures. Continuous monitoring is
carried on to ensure that the hazard is under control.
For detail check HACCP Plan -PFP/QR/HACCP/010

4.8 Monitoring Procedures
Monitoring is essential part of our HACCP system. It warns us if there is a

trend towards loss of control, so that to take action, based on an analysis of
the variation to bring the process back into control before a critical limit is
exceeded. Monitoring is a planned sequence of observations or measurements
to assess whether a CCP is under control and to produce an accurate record
for future use in verification. There are two types of monitoring:
 Continuous Monitoring
 Non-continuous Monitoring
Continuous monitoring at a CCP usually is done with measuring equipment.

Continuous monitoring is better because it results in a permanent record that
helps to review and evaluate to ensure that the CCP is under control. For this
purpose regularly check of continuous monitoring equipment is important for
accuracy. Non-continuous monitoring is used where continuous monitoring is
not possible or feasible. Non-continuous monitoring includes:
 Visual examinations
 Monitoring of raw material/ingredient specifications
 Measurements of pH and product cooling/or temperature
 Attribute sampling etc.
In non-continuous monitoring, it makes sure that the frequency of monitoring

is enough to ensure that the hazard is under control and that the monitoring is
performed at random times.
HACCP team is responsible to establish a frequency that ensures the CCP is
under control. For smooth monitoring HACCP team:
 Clearly identify the employee(s) responsible for monitoring.

 Train the employee(s) monitoring the CCPs in the testing procedures, the
critical limits established, the methods of recording test results, and actions
to be taken when critical limits are exceeded.
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 Ensure that the employee(s) understand the purpose and importance of
monitoring.
HACCP Team takes the following steps in establishing the monitoring

procedures:
 For each CCP, identify the best monitoring procedure.

 Determine the frequency of monitoring for each CCP.
 Determine if the monitoring activity needs to be done randomly to get a good
representation of the product throughout the production. If it does, decide
how the random monitoring will be done.
 Determine what testing procedures need to be done for each monitoring
function.
 Identify and train the employee(s) responsible for monitoring.
 Make sure that the employee doing the monitoring signs all records and
documents associated with CCP monitoring. Also make sure that the
monitoring results are documented or recorded at the time the monitoring
takes place.
4.9 Corrective Actions
Corrective Actions are followed when a serious or critical deficiency is assessed

or when a critical limit is reached or exceeded. When critical limits are
exceeded at a critical control point, corrective actions are taken to eliminate the
hazard created by the deviation. These actions also assure proper disposition of
the product involved. HACCP team takes the following steps in establishing
corrective actions:
 For each CCP determines the corrective action if the critical limits are
exceeded. Determine what should be done with the product if a deviation
occurs at this step.
 Develop the record form to capture all the necessary information on the
deviation, and identify the employee responsible for maintaining and signing
the record.
 Ensure that employees conducting the monitoring at each CCP are fully
trained and know the corrective actions to take if a deviation occurs.
 Enter the appropriate corrective action(s) for each CCP in the corrective
action.
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HACCP team develops specific procedures for critical limits of critical control
points. This is due to variations in product and the diversity of associated
deviations. The corrective Actions involve:
 A statement of the problem

 Procedures for handling of the product
 Identify the person responsible for the corrective action
 Testing to establish the acceptability (if applicable)
 Final disposition of the product
 Documentation and signatures
For further detail check

“Corrective & Preventive Actions -PFP/QR/HACCP/011”
When a deviation from a critical limit occurs and there is no proper corrective
action is taken that is appropriate for the deviation, then the HACCP team is
responsible to:
 Segregate and hold the product, perform the review to determine

acceptability
 Take corrective action, when necessary with respect to the affected product
 Take corrective action when necessary to correct the cause of the deviation
 Perform timely verification and maintain records related to corrective
actions
 Correct the cause of the non-compliance to prevent a recurrence
 Demonstrate that CCP is once again under control. (Examine that the
process or product again at that CCP and getting results that are within the
critical limits).
4.10 Verification Procedures
HACCP team is responsible to verify that a HACCP system is implemented
according to the design.
A. Verification
HACCP team has put into place the HACCP plan and carries out verification
activities on an ongoing basis. Verification entails the use of methods,
procedures, or tests in addition to those used in monitoring, to determine
whether the HACCP system is operating as intended. It consists of a periodic
review to determine the overall effectiveness of the HACCP plan (HACCP
Internal Audit). Both the HACCP team and the HACCP auditor or regulatory
agencies have a role in verifying HACCP plan compliance. Verification confirms
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that all hazards are identified in the HACCP plan when it was developed.
Verification activities include:
 Review of any customer complaints

 Calibration of process monitoring instruments at specific intervals
 Direct observation on monitoring activities
 Review of the records that relate to,
a) The monitoring of the critical control points
b) The taking of corrective actions
c) Calibrate any process monitoring instruments used at critical control
points
 Inspections of the facility as to conformance with the facility’s HACCP plan
and established regulations
 Sample collection and analysis to support inspections/observations
 Physical, chemical, and sensory examinations for conformance with
specification standard criteria
 Testing for conformance with biological criteria where established
HACCP team leader ensures that employees follow the procedures for taking
corrective actions when a critical limit is exceeded. He routinely checks to see
that employees are keeping specific, accurate, and timely HACCP records. He
verifies HACCP system as under:
 Calibrate temperature/test equipment;

 Sample product, including microbiological sampling;
 Review monitoring records;
 Review records of deviations and product dispositions;
 Inspect establishment’s operations;
 Sample for environmental and other concerns.
For further detail check

“Corrective & Preventive Actions -PFP/QR/HACCP/012”
B. Validation
Validation of HACCP plan ensures its implementation and prevents, eliminates,
or reduces to a regulated and/or commercially feasible and appropriate level
the identified microbiological, chemical, and/or physical hazards. HACCP team
is responsible for the validation of HACCP plan and ensures that it is adequate
to control the food hazards that are reasonably likely to occur. This will be
done at least once a year after implementation or whenever any change in the
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process occur that could affect the hazard analysis or alter the HACCP plan in
any way. The change that affects the HACCP Plan includes the following:
 Raw materials or source of raw materials

 Processing methods
 Packaging
 Finished product distribution system
 Customer/Intended use of the product
The HACCP plan is modified immediately whenever a deviation reveals that the
plan is no longer adequate to fully meet the requirements. HACCP team
reassesses the HACCP plan when:
 New hazards have been identified that is introduced into the

process/product
 Add new raw material/ingredients
 Change the process steps or procedures
 The introduction of new or different processing equipment
 Production volume & or personnel changes
 End point consumer for the product or the distribution system changes
The reassessment covers the review of existing HACCP plan and system
including the hazard analysis, critical control points, critical limits, monitoring
procedures, record keeping, and corrective actions to determine that they still
assure process control over food safety hazards.
4.11 Documentation & Records Keeping System
Organization has established an efficient & effective documentation & records

keeping system to ensure that the product safety & compliance meets with the
requirements of applicable HACCP standards. This system ensures that all the
necessary documents (manual, procedures, work instructions & formats) are
available where required & obsolete documents are promptly removed from al
locations. HACCP team prepares and maintains the following records
documenting all the elements of HACCP system:
 Description of HACCP system

 Records related to HACCP manual.
 Records related to Antemortem & Postmortem Inspection.
 Records related to Sanitation Standard Operating Procedures.
 Records related to current Good Manufacturing Practices.
 Written hazard analysis including modification if any.
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 Written Critical Control Point Determination.
 Written HACCP plan.
 Records related to HACCP plan including monitoring CCP’s & corrective
actions.
 Record related to verification of HACCP system and validation of HACCP
plan/or hazard analysis as appropriate.
 Record related to modification of HACCP system.
 Record related to internal & external audits.
 Record related to complaint, recall & training.
All records related to HACCP system is retained for minimum one year. It is
ensured that all records have, name, date, time of activity and signature of the
individuals performing the activity. For each critical control point, HACCP
Team prepares records that demonstrate monitoring procedures and corrective
actions being taken.
The types of records demonstrate adequate documentation that critical control

points are being controlled which are:
 Records showing critical control points are being monitored. The critical
limits are incorporated on the monitoring record as a constant reminder to
the examiner or observer.
 Records documenting an unusual occurrence and the corrective action
taken if critical limits are not met/or are exceeded. These records include
disposition of the product(s) involved. If the decision is made to use the
product, indicate under what conditions it was maintained pending
evaluation. All reports of corrective actions are kept in a separate file with
copies attached to the monitoring record where the problem occurred.
 Records showing that instrumentation or other equipment necessary to the
monitoring process have been properly checked for accuracy and reliability,
and are being properly maintained and or calibrated.
Organization develops a strict record keeping system that demonstrates control

over critical control points and will:
 Advise abattoir management regarding the performance of HACCP plan.

 Provide evidence of a proper and safe operation.
 Serve as a mechanism for indicating potentially serious problems and
assisting the responsible individual(s) in the determination of a proper
corrective action.
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An efficient filing system is set up for all of these records and forms. All of the
records and forms in this filing system are accessible. Organization set up and
maintains record keeping system that will provide the following information:
 Early detection of areas of concern.

 Isolation of a problem or potential problem is made easier.
 Trends can be identified which may require more supervision.

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Document # MWPL/HACCP/001

HACCP System Manual

Document Copy # 01 Issued Status: _____________________

Activity Name/Designation Signature Date

Mr. Muhammad Shahid

Mr. Raja Faisal Shehzad

S. No. Contents Page #

0.0 AMENDMENT SHEET

1.0 PURPOSE & SCOPE

This HACCP manual is applicable to all the operations of slaughterhouse from

Top management takes the HACCP program as a technique, process & a

 Sanitation Standard Operating Procedures (SSOP’s)

Organization applies this unified comprehensive and systematic approach to:

 Assess the hazards to products and to decide on the control measures to

HACCP System Definitions

3.0 PREREQUISITE PROGRAMS

3.1 Management Assurance

Top management of PFP is fully committed to food safety program and

 Communicating at all levels in the organization the importance of meeting

 Performing management reviews and ensures that HACCP system

Functions and their interrelationships within the organization including

Pakistan Food Products maintains internal communication through feedback,

 Organizational Chart MWPL/QR/MGT/001

3.2 Food Safety Policy

 Is appropriate to the purpose of the organization

Organization is committed to set, implement & maintain high standards of

Top management will;

 Always purchase healthy livestock.

3.3 Sanitation Standard Operating Procedures

The regulatory requirement for Sanitation Standard Operating Procedures

 Construction & layout.

Top management is responsible:

 For the implementation and control of these sanitation requirements.

Records related to these requirements are maintained within slaughterhouse in

Sanitation standard operating procedure (SSOP) controls are not included

Organization has developed & implements a documented training procedure for

HACCP Team Leader is responsible to train all employees in the procedures

 The employee is given verbal counseling.

Records are kept of employee participation in training activities and used to

3.5 Product Recall/Withdrawal

Organization has a system in place to effectively manage incidents and enable

 Chief Executive Mobile: 92

Product Recall/Withdrawal Team is committed to manage effectively all

If during processing of meat any deficiency is found and there is requirement

Organization develops a customer complaint file and handles customer

4.0 HACCP PLAN REQUIREMENTS

 Assemble the HACCP team.

For detail check “HACCP Plan – MWPL/QR/HACCP/010”.

Management Commitment & Understanding

4.1.1 Flow chart of logically HACCP plan development & implementation

Describe product & identify intended use

Construct flow diagram

On site verification of flow diagram

Identify hazards & describe preventive

Identify critical control points

Establish critical limits for each step

Establish a monitoring system for each CCP

Establish corrective actions for deviation

Establish verification procedures

Establish record keeping & documentation