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HACCP/BRCGS and Hygiene Quality Awareness training. 2019 version 1 In compliance with BRC S&D issue 3 and BRC A&B issue 2. HACCP/BRCGS and Hygiene Quality Awareness training 2019 In compliance with BRC S&D issue 3 and BRC A&B issue 2 Duration: 45 min Mobile phones on silent please.
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HACCP/BRCGS and Hygiene Quality Awareness training 2019 version 1 In compliance with BRC S&D issue 3 and BRC A&B issue 2
HACCP/BRCGS and Hygiene Quality Awareness training 2019 In compliance with BRC S&D issue 3 and BRC A&B issue 2 Duration: 45 min Mobile phones on silent please • Source: N&S Quality -Zaltbommel
Agenda • What is HACCP/BRCGS? • Why carry out HACCP/BRCGS training? • Hazards • Measures for control • Certifications • Instructions for drivers
Why HACCP/BRCGS & Hygiene course • Promote Hygiene Awareness • Prevent contamination caused by: • Lack of knowledge • Lack of care and attention • Lack of hygiene • Failure to maintain correct temperature • Ensure safe delivery of product to the customer in good quality • Ensure competency of staff
Certification Standards Recognised by Global Food Safety Initiative • HACCP Hazard Analysis Critical Control Points • BRCGS British Retail Consortium Global Standard • BRC Storage & Distribution Standard applies to the Temperature Controlled Activity in Europoort, where we operate our own Reefer trailers. • BRC Agents & Brokers Standard applies to the services supplied by the Control Tower in Amsterdam and the Dover office, which utilises third party sub-contract hauliers who use their own equipment. • IFS International Food Standard • FSSC 22000 Food Safety System Certification 22000, based on ISO
What is HACCP/BRCGS ? • Origin • Mapping product and process • Identify hazards to public health and set standards • Risk-analysis • Control method indication • Protection procedures • Documentation
Background and Scope • To demonstrate to our customers that P&O Ferrymasters transport their products in a safe and secure way, we hold two BRCGS certifications; BRC Storage and Distribution and BRC Agents and Brokers for the transportation of ambient, chilled and frozen packed food products. • British Retail Consortium Global Standards (BRCGS) specify that businesses must have a full understanding of the products handled and transported and have systems in place to control hazards significant to the safety and quality of the products.
Certification - requirements • Manufacturers, food companies and suppliers must have a valid food safety system, such as HACCP / BRCGS certification. • All companies involved in the supply chain must comply to this standard. • BRC S&D and A&B Gradation AA, A, B, C, D in line with BRC food certification • Possibility to participate in unannounced audits. This is also in line with the BRC Food certification. When participating a “+” is added to the grade. (for example, AA+)
Certification - Audits • Document Control • Initial visits • Follow up visits • Possibility of un-expected visit by ‘BRC auditor’ Results of external audit? All audits must have a positive result!
Internal audits • Checking application of food safety controls and compliance with company policies and procedures (to be found on the intranet). • Be honest and learn from the shortcomings • Preparation for certification • Create and increase ownership and engagement • Internal audit to cover, product security / food defence and product fraud mitigation plans.
Hazards • Not following company and client procedures • Improper Haulier approval and subcontractor management • using hauliers other than those approved for Foodstuffs by POFM • Not receiving or giving the correct instructions • Lack of engagement from management and employees • Equipment does not comply to required standards • Failure to set / monitor temperature in Reefer trailers and complete / control Driver Reports. • Failure to log incidents, investigate and implement corrective actions to prevent re-occurance • Lack of employee awareness and knowledge
Control measures • Identification of CCP’s • Control processes and procedures • Management of Suppliers • Cleaning programs • Equipment Maintenance and Calibration • Temperature controls and checks • Supply of controlled, calibrated temperature probes to drivers of POFM reefer trailers. • Deviation and incident management • Pest Control and Waste management (more specified in S&D V3 standard) • Hygiene rules for drivers
CCP’s in Transport • Critical control points (as applicable); • Temperature control (calibrated measuring equipment) • Hygiene • Prevention of contamination (illegal immigrants) • Use of authorized Hauliers with trained drivers • Product damage during transit (load securing) • These points must be checked and documented! • Any deviations must be reported immediately to your manager
Why practice good hygiene (1) • Approx. 2 mil. People become ill each year by contaminated food (Bron Nationaalkompas, based on Netherlands, population of circa 16 mil) • 80 deaths each year by contaminated food (Bron Nationaalkompas, based on Netherlands, population of circa 16 mil)
Why practice good hygiene (2) • €220 mil. Financial damage • Recalled products • Quality reduction • Damage to company reputation • Claims • Fines / Official warnings Nederlandse Voedsel en Waren Autoriteit (NVWA) • It is not allowed to do transports for clients in the food industry without HACCP/BRC Quality Systems!! • Requirement of clients
HACCP / BRCGS • The substances or objects that may cause harm to your health which are undesirable we call contaminants. • There are several types of contaminants such as : • Physical • Chemical • Microbiologica
Physical Contaminants • Remnants from previous products • powders, dusts, sand, wood • Nails and Screws • Glass • Cigarrete butts • Fragments from tools • Other physical items
Chemical Contaminants • Residues: • Cleaning products • Lubricating oils • Coolants • Plant protection products • Fertilizers • Chemical contamination is often not noticed by the consumer: it may be substances without odour, colour or taste in small quantities and can seriously damage health
Microbiological Hazards • (1 gram = 100,000 billion pieces) • Fungi • Yeasts • Bacteria Micro-organisms may be desirable and undesirable in food products
What are micro-organisms? Salmonella Staphylococci E. coli
Growth of bacteria Time Amount • 1 hr 8 • 2 hr 64 • 3 hr 512 • 4 hr 4.096 • 5 hr 32.768 • 6 hr 262.144 • 7 hr 2.097.152 • 8 hr 16.777.216 • 9 hr 134.217.278 • 10 hr 1.073.741.824
Allergens • An allergen is a component of a natural, or artificial substance which may cause allergic reactions. Symptoms may include a runny nose, watery eyes, itching or tightness. Allergic reactions are often related to conditions such as eczema (skin reactions) and asthma (respiratory reactions). • The number of substances that can act as an allergen is virtually unlimited.
Food Defence and Fraud, theft, or substitution The following factors can increase the risk of fraud or theft of food products:- • National or European shortage of product supply = higher value of product • Desirability of products • Economic conditions = higher unemployment, low wages • Changes in taxation = increases taxes on specific products • Security breach by illegal immigrants during transit = contamination of product
Incidents (Negative Publicity) • Sweet manufacturer Mars carried out a major recall in 55 countries when pieces of plastic were found in a Mars bar in Germany. Accordingly products from brands Mars, Snickers, Milky Way, Mini Celebrations and Mini Mix were recalled from the shops. • 4 million bars in the Netherlands and 10 million in Germany. It is the first time Mars carried out a recall from their factory in the Netherlands. It works closely with the NVWA and retailers to recall the bars in this batch, from the supply chain, as quickly and completely as possible. Thereafter, the chocolate was destroyed. • Lactalis factory in Craon, due to salmonella bacteria in baby food three dozen infants in France have been confirmed sick and a number of children in Spain and Greece may be sick from contaminated Lactalis products.
Traceability & recall • Everything must be traceable (including raw materials and primary packaging) • Full traceability should be completed within 4 hours • The recall procedure should focus on communication with customers (communication plan) • Identification: everything must be encoded • Decide on recalling and report to authorities and certification bodies (NVWA and DNV) • Register what is done with return product • The suppliers shall have an effective traceability system. If a supplier has been approved based on a questionnaire, a legally enforceable contract shall be in place. Verification of the supplier’s traceability system shall be carried out at the time of the initial approval and then at least every 3 years.
Complaints and Incidents • In emergency situations immediately notify POFM, who will inform the client • What are the complaints? • Register complaints in the incident tab (fr8 orders) • Detect deviations and report to your manager • Investigate and close out incidents and complaints in fr8orders • Make sure you learn from mistakes
Management of Suppliers – BRC Charter Haulier 13. Carrier Questionnaire Carriage of foodstuffs Asset haulier 7. Haulier Questionnaire Approval procedures can be found on the intranet: > Logistics Service Providers • Foodstuff • Audits, training, probes
Cleaning Programs • Schedule: daily, weekly, monthly or yearly • What to clean • Which products to use • Who does the cleaning • How often • Record and document the check! • Cleaning station questionnaire returns to confirm station complies with Food Safety standard
Hygiene regulations (1) • Clean Clothing • No Smoking, eating, chewing and drinking during loading and unloading • Do not wear jewellery • Wash hands frequently (After breaks and after toilet visits) • Clean equipment • Open wounds must be covered with plaster
Hygiene regulations (2) • Report incidents of contamination to management: pests, glass and hard plastic • Inform management in case of infectious diseases (such as Diarrhoea) and skin complaints • Comply with site rules. This may include wearing protective coats, gloves and hair nets in the production areas • Avoid coughing on uncovered foods • Avoiding touching the products
Precautions • In places where hand hygiene is crucial, the following precautions are necessary: • Keep finger nails short and clean • No gel or plastic nails • Remove all nail polish in advance • Do not wear hand or wrist jewellery, watches etc. • Remember to also thoroughly wash the wrists and forearms
Handwashing Guidance • Wet your hands • Take a dose of soap in the palm • Rub the palms well for at least 30 seconds each • Turn right thumb movement on the left palm. • Left palm over back of right hand. • Turn fingers on the palm of the other hand. • Palms crossed, fingers spread. • Dry hands
Certain areas need special attention when washing hands Often forgotten Is frequently forgotten Normally well cleaned Back of hand Palm
Equipment requirements for All trailers • Check trailer is clean (swept inside) • Check there is no residual smell from previous product • Check trailer condition: - trailer floor for loose nails and defects - curtains and roof for holes and tears (check it is watertight) • Check TIR cord is present (where applicable)
Operational Instructions for All trailers • After loading, seal trailer with TIR Cord, or lock trailer with padlock • Record seal number on CMR in presence of loading team • On route to port or rail terminal:- • Complete checks in line with UK Border Force Checklist • Plan to avoid overnight rest and stops within 150km of Ports. • Refer to Illegal Immigrant instructions: • http://www.poferrymasters.com/customers-and-partners/partner-information/instructions-for-subcontractors
Equipment requirements for Reefer Trailers • Trailers must comply with legal standards, maintenance, cleaning, FRC checks (for reefer trailers) • Calibrated temperature monitoring and recording equipment • No fragile glass (example light in reefer trailers) • No wood (except pallets)
Maintenance/Calibration for Reefer Trailers • Calibration of measuring equipment (e.g. temperature probes) • When servicing equipment use only "suitable for food’’ oils / lubricants • External technicians must comply with hygiene rules • Be aware of loose equipment
Specific instructions for Reefer Trailers • The following two slides are an extract from our Haulier Handbook and Instructions to Subcontractors. • The operation of Reefer Trailers is a specialised activity • The consequences of incidents can be dangerous to health and are costly. • Reefer trailers are far more expensive than euroliner trailers and specific knowledge is required.
