HACCP Level 1, 2, 3, 4 Combo Training

1. 1. Introduction to Food Safety

• Importance of food safety

• Foodborne diseases and outbreaks

• Types of food hazards

  • Biological

  • Chemical

  • Physical

  • Allergen hazards

• Sources of contamination

• Preventing cross-contamination

• Food safety culture in the workplace

2. Good Hygiene Practices (GHP) & Good Manufacturing Practices (GMP)

• Personal hygiene & handwashing

• Food handler health & hygiene

• Cleaning and sanitation (SSOP)

• Equipment & facility hygiene

• Water quality and air handling

• Waste management

• Pest control

• Allergen management and control

• Storage & temperature control

• Traceability and recall basics

3. Introduction to HACCP

• What is HACCP?

• History and purpose of HACCP

• Benefits of implementing HACCP

• Legal requirements (FSSAI + Codex)

• Role of food handlers, supervisors, QA team, and management

4. Prerequisite Programs (PRPs)

• GHP/GMP requirements

• SSOP (Sanitation Standard Operating Procedures)

• Chemical control and management

• Supplier management

• Receiving and storage controls

• Calibration and maintenance

• Glass/brittle plastic policy

• Environmental monitoring

5. HACCP Principles – The 7 Steps

1. Conduct hazard analysis

2. Determine CCPs

3. Establish critical limits

4. Establish monitoring procedures

5. Establish corrective actions

6. Establish verification procedures

7. Establish documentation & record keeping

6. HACCP Plan Development

• Product description & intended use

• Identification of target consumers

• Preparation of process flow diagram

• On-site verification of flow diagram

• Detailed hazard analysis (severity × likelihood)

• Determining control measures

• CCP vs OPRP decision tree

• Setting and validating critical limits

• Monitoring requirements

• Corrective actions & preventive actions

• Verification & validation activities

• Master list of records and documents

7. Risk Assessment Tools

• Risk matrix development

• Severity & probability scoring

• FMEA approach (optional)

• Assessing biological, chemical, physical hazards

• Allergen risk assessment

8. Internal Auditing 

• Types of audits: internal, supplier, 3rd party

• Audit planning & preparation

• Audit tools and checklists

• Interviewing techniques

• Non-conformity identification

• Root cause analysis

• CAPA (Corrective and Preventive Actions)

• Writing audit reports

9. Advanced HACCP & FSMS Integration (Level 4)

• Relationship between HACCP, ISO 22000, FSSC 22000, BRCGS

• OPRP vs CCP determination

• Verification vs validation

• Advanced documentation requirements

• Scientific validation of control measures

• Continuous improvement in HACCP plans

10. Food Defense & Food Fraud (VACCP & TACCP)

• Understanding threats and vulnerabilities

• Food defense plan development

• Intentional adulteration

• Economically motivated adulteration (EMA)

• Mitigation strategies and controls

11. Case Studies & Workshops (All Levels)

• Identify hazards in real scenarios

• Develop a sample HACCP plan

• CCP identification exercises

• Mock inspection & mock recall

• Live audit simulation (Level 4)

12. Assessment & Certification