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GOOD MANUFACTURING PRACTICES Training about our Food Safety Program. HACCP ACRONYM. H azzard A nalysis C ritical C ontrol P oint. HISTORY OF THE HACCP SYSTEM. HACCP was developed in the 1960 ’ s when NASA asked Pillsbury to design and manufacture the first food for space flights
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GOOD MANUFACTURING PRACTICES Training about our Food Safety Program
HACCP ACRONYM Hazzard Analysis Critical Control Point
HISTORY OF THE HACCP SYSTEM • HACCP was developed in the 1960’s when NASA asked Pillsbury to design and manufacture the first food for space flights • The growing concern about food safety from public health authorities, the Food Industry and consumers world wide has been the major force in the introduction of the HACCP system. Today HACCP is accepted internationally as a useful tool for adapting traditional inspection methods to a modern, science based, food safety system. HACCP has become the globally recognized method to ensure food safety
WHAT IS HACCP? • HACCP is a systematic, preventative approach to food safety. It aims to prevent biological, chemical and physical hazards, instead of relying on finished product inspection. HACCP is used in the food industry to identify potential food safety hazards, so that key actions, known as Critical Control Points (CCPs) can be used to reduce or eliminate the identified hazards. • With HACCP the food processor systematically: • Identifies potential food safety hazards (Hazard Analysis). • Determines the key steps in their operation where the hazards can be prevented, eliminated or reduced to an acceptable level. (The key steps are known as Critical Control Points or CCPs)
KEY CONCEPTS OF A HACCP PLAN • Good Manufacturing Practices (GMPs) • Standard Operating Procedures (SOPs)
SOP’s ALLOW YOU TO: • SAY what you do • DO what you say • PROVE it
WHAT ARE CCPs (Critical Control Points)? • A CCP is a key step where hazards can be prevented, eliminated or reduced to an acceptable level.
THE SUCCESS OF HACCP AND THE SEVEN PRINCIPLES • Identify Hazards • Determine Critical Control Points (CCPs) • Establish Critical Limits • Establish Monitoring Procedures • Establish Corrective Action Procedures • Establish Verification Procedures • Establish Record Keeping
PREREQUISITE PROGRAMS • Premises (including water supply) • Transportation, Receiving and Storage • Equipment Design, Installation and Maintenance • Personnel Training • Sanitation & Pest Control • Recall
GOOD MANUFACTURING PRACTICES (GMPs) • You can control many of the potential hazards in a processing plant by using a standard set of principles and hygienic practices for the manufacturing and handling of food. These standard principles and practices are called Good Manufacturing Practices (GMPs)
GMPs ARE: • Preventative measures to ensure food safety • Based on practical experience over a long period of time • The foundation on which to build a HACCP program
STANDARD OPERATING PROCEDURES (SOP’s) • The purpose and frequency of doing a task • Who will do the task • A description of the procedure to be performed • What paperwork is to be completed (documentation) • The method by which you show that task is satisfactorily completed • And the corrective actions to be taken of the task is performed incorrectly
A CAR must be completed for each deviation from the SOP CAR Form CAR Instructions State deviation Use objective Evidence Develop an action plan to prevent deviation reoccurrence Set a deadline Verify that the action plan has been effective CORRECTIVE ACTION REQUEST
PREREQUISITE PROGRAM: PREMISES • Building Exterior • Building Interior: Design, Construction, Lighting, Ventilation, Waste Disposal, Inedible Areas • Sanitation Facilities: Employee Facilities, Equipment Cleaning & Sanitizing Facilities • Water/Ice Quality and Supply
PREREQUISITE PROGRAM: PREMISES • Premises SOP • Monitoring Procedure: part of internal audit procedures
PREREQUISITE PROGRAM: TRANSPORTATION, RECEIVING & STORAGE • Receiving:Food Carriers, Temperature Control, Approved Suppliers • Storage:Ingredient, Allergen, Finished Product and Chemical Storage • Transportation:Food Carriers, Temperature Control
PREREQUISITE PROGRAM: TRANSPORTATION, RECEIVING & STORAGE • Transportation Receiving and Storage SOP • Monitoring Procedures: check each shipment, • CAR: example • Allergen Program • Approved Suppliers Program
PREREQUISITE PROGRAM: EQUIPMENT • Equipment Design and Installation • Equipment Maintenance and Calibration • Equipment SOP • Temperature Monitoring Log • Thermometer Calibration
PREREQUISITE PROGRAM: PERSONNEL • Training: Hygiene and Technical • Hygiene and Health Requirements • Personnel SOP • Employee Sanitation SOP • Visitor Log Book Good Management Practices Dec-07
PREREQUISITE PROGRAMS: Sanitation & Pest Control • SANITATION • PEST CONTROL • SOP • PREOPS CHECKLIST • TRUCK CLEANING LOG
PREREQUISITE PROGRAM: RECALL • The Recall System • Complaints Log • Complaints Log SOP • Recall Template • Recall Notice • Allergen Alert Notice
CRITICAL LIMITS • Is a value which separates acceptability from unacceptability • Critical Limits must meet or exceed government regulations • One or more critical limit must be met to ensure a CCP is controlling the hazard
CRITICAL LIMITS • Temperature / Time • pH • Aw (available water) • Preservatives • Available chlorine • Sensory observations
SOURCES OF CRITICAL LIMITS • Regulatory Standards • Company Standards • Literature Surveys • Experimental Studies • Expert Advice
CRITICAL LIMITS • Individual Product Profiles • Process Control Sheet
PRODUCTION RECORDS • Using CIMS to record ingredients, batch processing and finished product information
IMPORTANCE OF VERIFICATION • Ensures that all major processing steps have been identified • Validates the assumptions made regarding the movement of employees and product • Works towards continual improvement of the GMP system
IMPORTANCE OF VERIFICATION • Internal Audit • Internal Audit Template • Label Review