OPRP or HACCP Plan - Opinions and Practical Example Wanted

S

Sveta

#1
Hello!

One of the examples I’ve heard a lot of times to understand difference between operational PRP and HACCP plan is example with metal detector. Last metal detector on the production line is a CCP and managed by HACCP plan and all other metal detectors are not CCP and managed by operational PRPs. Theoretically all is clear. Let’s see what we get in practice. In practice we don’t have any difference in managing all these metal detectors, we check them let’s say every 2 hr with the same samples (same critical limits), corrective actions are also the same. ISO 22000 doesn’t require critical limits for operational PRP, but in this example we have it anyway. So what is the point in this case to have two documents (operational PRP and HACCP plan)?
Any comments?:thanx:
 
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B

Bilijaf

#2
Re: OPRP or HACCP plan - practical example

Hi,
I think all metal detectors are to be considered as CCP's, since they are installed to eliminate metal traces and no further step will eliminate them.
If you think that metal hazard are not significant at any of the processing lines and you placed metal detectors for more security, in that case you can consider them as OPRP where frequent monitoring is not necesary.
I all cases ask yourself the questions: Is it possible to monitor the control measure in such a way that corrective actions can be taken immediately when there is a loss of control? Is it possible to establish critical limits for the control measure at this step? , if both answers are yes so this point is a CCP, otherwise it is an OPRP.
 
S

Sveta

#3
Re: OPRP or HACCP plan - practical example

Hi Bilijaf!
Thanks for reply.


I am not sure that all metal detectors are to be considered as CCP's. If 3 metal detectors ate installed in one production line then only after last of them there is no further step to eliminate the hazard.
So it must be decided upon results of analysis.


Moreover, according to ISO 22000 it doesn’t matter what way of managing of control measures you will choose as anyway they should be:
7.4.4“…capable of preventing, eliminating or reducing these food safety hazards to defined acceptable levels”
8.2 “Prior to implementation of control measures to be included in operational PRP(s) and the HACCP plan and after any change therein (see 8.5.2), the organization shall validate (see 3.15) that
a) the selected control measures are capable of achieving the intended control of the food safety hazard(s) for which they are designated, and
b) the control measures are effective and capable of, in combination, ensuring control of the identified food
safety hazard(s) to obtain end products that meet the defined acceptable levels.”

And one more point, you put only two questions to categorize between operational PRP(s) and HACCP plan, though according to ISO 22000 sec.7.4.4 there are many others:
“The selection and categorization shall be carried out using a logical approach that includes assessments with regard to the following:
a) its effect on identified food safety hazards relative to the strictness applied;
b) its feasibility for monitoring (e.g. ability to be monitored in a timely manner to enable immediate corrections);
c) its place within the system relative to other control measures;
d) the likelihood of failure in the functioning of a control measure or significant processing variability;
e) the severity of the consequence(s) in the case of failure in its functioning;
f) whether the control measure is specifically established and applied to eliminate or significantly reduce the
level of hazard(s);
g) synergistic effects (i.e. interaction that occurs between two or more measures resulting in their combined
effect being higher than the sum of their individual effects).
 

Marc

Hunkered Down for the Duration with a Mask on...
Staff member
Admin
#4
As reference for those who are not 'literate' in this, but follow the topic for educational purposes:

Critical Control Point (CCP) - A critical control point is the point (or step) at which a control measure must be applied. It is a point that is critical or essential to safety. It is the point where a control measure can be used to prevent or eliminate a food safety hazard or to reduce it to an acceptable level.

OPRP = Operational Prerequisite Programs

HACCP = Hazard Analysis & Critical Control Points
 
B

Bilijaf

#5
Re: OPRP or HACCP plan - practical example

hi bilijaf!
Thanks for reply.


I am not sure that all metal detectors are to be considered as ccp's. If 3 metal detectors ate installed in one production line then only after last of them there is no further step to eliminate the hazard.
So it must be decided upon results of analysis.
i am not sure if it is worthy to have metal detector at earlier stages of processing. The best location for it is directly before final wrapping or packaging where a further physical hazard is excluded.
moreover, according to iso 22000 it doesn’t matter what way of managing of control measures you will choose as anyway they should be:
7.4.4“…capable of preventing, eliminating or reducing these food safety hazards to defined acceptable levels”
8.2 “prior to implementation of control measures to be included in operational prp(s) and the haccp plan and after any change therein (see 8.5.2), the organization shall validate (see 3.15) that
a) the selected control measures are capable of achieving the intended control of the food safety hazard(s) for which they are designated, and
b) the control measures are effective and capable of, in combination, ensuring control of the identified food
safety hazard(s) to obtain end products that meet the defined acceptable levels.”

not in that sense, i can understand a ccp as having higher level of control than oprp where you have define control limits at close intervals of monitoring. I would not use examples here since we need to consider the full flow and not individual processing step. and one more point, you put only two questions to categorize between operational prp(s) and haccp plan, though according to iso 22000 sec.7.4.4 there are many others:
“the selection and categorization shall be carried out using a logical approach that includes assessments with regard to the following:
a) its effect on identified food safety hazards relative to the strictness applied;
b) its feasibility for monitoring (e.g. Ability to be monitored in a timely manner to enable immediate corrections);
c) its place within the system relative to other control measures;
d) the likelihood of failure in the functioning of a control measure or significant processing variability;
e) the severity of the consequence(s) in the case of failure in its functioning;
f) whether the control measure is specifically established and applied to eliminate or significantly reduce the
level of hazard(s);
g) synergistic effects (i.e. Interaction that occurs between two or more measures resulting in their combined
effect being higher than the sum of their individual effects).[color="red"right. [color="red[color="red"]"]i was talking only about how to differenciate between them. Above points are assessment criteria or approach used for both ccp and oprp.[/color][/color]
[/color]
 
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R

Robert jr

#6
Hello,

As far as I am aware a number of food manufacturers do not consider metal detection as CCP or removed it recently from being CCP.

In terms of OPRP or HACCP, the OPRP is foundation for HACCP in an overall food safety management programme. A proper and well designed prerequisite programme allows the HACCP team to focus and concentrate on the hazards directly applicable to the product and the processing procedures without undue considerations and repetition of protection from hazards from the surrounding environment.
 
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