1 Day Awareness HACCP-PDF

FOOD SAFETY & HACCPAwareness Program

ForM/s. Pepsico India Holdings

Pvt. Ltd.Dharwad

Suhas Bedekar SGS India Pvt. Ltd.

THE SGS GROUPExpertise, Everyday, Everywhere ...

SGS established in 1878 as French grain shipment inspection house, registered in Geneva as SGS (Société Générale de Surveillance) in 1919, is the clear global leader and innovator in inspection , verification , testing and certification company.

SGS is recognized as the global benchmark for quality and integrity.

Represented in over 140 countries

1,260 offices

365 laboratories

46,000 full time employees

North America100 offices105 laboratories

Latin America98 offices30 laboratories

Europe422 offices115 laboratories

AfricaMiddle East137 offices39 laboratories

Asia - Pacific212 offices54 laboratories

With Global capability at your service

1878Agriculture

Minerals

Industrial & Consumer Products Testing

Petrol & Petrochemicals

Services to Govt. & Institutions

Bio Sciences / Environment

Certification

2007

Services to Insurance Industry

We provide leading &

innovative services

Certification

Inspection

Verification

Outsourcing

Risk Management

Testing & Analysis

Training

In the areas of

SGS in India

Founded in 1950

Headquarters in Mumbai

ISO 9001:2000 Certified

35 offices

17 Laboratories

Nearly 2700+ people

To all industries

Industrial

Life Sciences

Minerals

Oil, Gas & Petrochemicals

Systems and services certification

Agriculture

Automotive

Consumer Products

Environment

Government & Institutions

An Real Life example of what happens to a company.

That did not understand the importance of

FOOD SAFETY.

Food Safety Incidents in Asia

Milk company profit plummets

from US$ 84 M

to a loss of

US$ 442 M. In excess of 14,700 consumers

with food poisoning.

More than 14,700 consumers affected with Food Poisoning

July 22, 2000

Product Recall beganJune 29, 2000

Product Recall RequestedJune 28, 2000

Snow Brand (Japan)

Brand sales dropped by 80%Aug 5, 2000

How did all this happen?

Insight can only suggest why it happened:The recession of the 1990’s forced cost cutting measuresStaff retrenchment - lost people with experience

Inadequate staff trainingTemporary equipment used permanently (no CIP system)No technical support guidelinesProduct recycled

Records were not accurate – avoidance of blameDecision making was delayed

Power failure resulted in holding milk at plus 30 deg C.

Staph.aureus grew and produced Enterotoxin A100 – 200 ng will cause illness

1 glass of low fat milk containing the tainted powder would havecontained between 80 – 160 ng of

Enterotoxin A

Warm milk processed into powder and finally used for

making milk.

What was the direct cause of the crisis?

THE FOOD SAFETY AND STANDARD ACT : 2006

OBJECTIVES OF THE ACT

1. To consolidate all the laws related to foods, standards and enforcement agencies2. To establish the Food Safety and Standards Authority of India, for(a) laying down science based standards(b) regulating manufacture, storage, distribution sale and imports by strengthening existing enforcement mechanisms(c) ensuring availability of safe and wholesome food for human consumption(d) making provisions for graded penalties(e) shifting from regulatory regime to self compliance employing FSMS

OBJECTIVE 1:INTEGRATION OF VARIOUS LAWS AND ORDERS

SPECIFIED IN THE SECOND SCHEDULE (SECTION 97)

1. The PFA Act (No. 37 of 1954)2. The Fruit Product Order, 19553. The Meat Food Products Order, 19734. The Vegetable Oil Products (Control) Order, 19475. The Edible Oils Packaging (Regulation) Order, 19986. The Solvent Extracted Oil, De-oiled Meal and Edible Flour

(Control) Order, 19677. The Milk and Milk Products Order, 19928. Any other order issued under the Essential Commodities Act,

1955 relating to food9. Any other law in force in any State upon Commencement of this

Act shall stand repealed

OBJECTIVE 2: ESTABLISHEMNT OF ENFORCING AUTHORITY

Central Government

Food Authority 23 members

Scientific Panels 8+

Central Advisory Committee47+11+3=61

CEO (Addl. Secy )

State Food Safety

Commissioners

Sectt.

Designated Officer (SDO rank) Licensing Officer

Chairperson

Enforcement

Scientific Committee

Food Safety Officer

Food Analyst

SCOPE OF THE ACT

primary foods (produce of agriculture, horticulture, animal husbandry, dairying, aquaculture);genetically modified foods and organic foods;infant foods;pre-packaged commodities;packaged drinking water;caterers;alcoholic drinks;chewing gums;substances and water used in the preparation of foods;food additives of all kinds.

EXCLUSIONS FROM THE ACT

Animal feedLive animals (not placed for marketing for human use)Produce of the farmers and fishermen at farm level Plants prior to harvestingDrugsMedicinal productsCosmetics, narcotics or psychotropic substances

UNSAFE FOOD MEANS

article of food or its package, composed wholly or in part of poisonous or deleterious substances;consisting wholly or in part any filthy, putrid, rotten, decomposed or diseased animal substance or vegetable substance;processing under unhygienic conditions or presence of harmful substances;substitution with any inferior or cheaper substance;presence of unpermitted additives, preservatives, colours, flavours, etc.;part or full abstraction of any constituent (adulteration);presence of worms, weevils or insects and extraneous matter;misbranded or concealed or unidentifiable foods;containing pesticides and other contaminants in excess of quantities specified by regulations;Best before date expired.

MANDATORY IMPLEMENTATION OF FOOD SAFETY MANAGEMENT SYSTEMS

(Time Frame requested by Food Industry Associations for adoption *)

2 yrHACCPLarge Scale,4 and 5 Star Hotels

4 yrGHP & GMP

Small and Medium Scale, 3 Star Hotels

5 yrGHPTiny Scale/Street Vendors

Time FSMSSector

* In response to Draft Notification GSR No. 578 dated 20.9.2006 by MOH.

Two month period was given to send the comments o MOH

NOW ISN’T THETIME TO THINK

ABOUT FOOD SAFETY &

QUALITY

PUBLIC ACCEPTANCE

Needs Safety &

Quality

Then Is it acceptable ?

Physical Hazard with Pizza

Hair is complimentary

Do You Know what is behind the bread served beautifully in hotels in the basket ?????

Food Safety / HACCP with SGS

Major food scares, poisoning, GMO’s, chemical residues have all highlighted the imperative to;

Manage risk across the entire food chain (A paddock to plate approach)

Move from the old end of line product inspection approach (often by government inspection agencies) to a new environment of quality assurance approach where the supplier assumes responsibility for safety.

“BRAND PROTECTION”

The Need

The Answer

An Integrated company-wide “Quality Management System” that;

Manages food safety issuesBuilds in customer product quality requirements Meets regulatory & market requirementsIs cost effective and makes money

Why Protect Customers

It is illegal to be unsanitary

Very Young and the elderly are more susceptible

Good food protection lowers costs

Good sanitation promotes repeat patronage

Key Points

All food service establishments have the potential to cause foodborne illness

Errors can occur at any stage : purchasing, receiving, storing, preparing, serving, cooling, and re-heating

Most victims of foodborne illness do not readily identify the source.

Customers / Increased incidents of Food Borne Illness

Regulatory Bodies (Governments) Food Bill

World Health Organization (CODEX)

Market Access (EU / USFDA )

Shareholders, Insurers (Litigation/Claims)

Retailers&Private Labels (Brand Protection)

What is Driving Food Safety

Food Safety Issues “Bangkok Post”

Sept. 1996 - Pesticides Laced VegetablesMar. 1996 - PreservativesMar.2002 - antibiotic in prawn/chicken meat

Never has Food Safety come under such scrutiny.Regulators are increasingly active in safeguarding food.

Globalisation and dismantling of trade barriers means suppliers have to compete on equal terms.

Customers are better educated and informed and are demanding:

SafetyConsistency of qualityValue for money

FOOD SAFETY ELEMENTS

HACCP principlesPrerequisite programs

Interactive communication

System management

Causes of Food Safety Problems

PEOPLE

FOOD FACILITIES

The Major Causes of Food Borne Incidence are;

Supply of poor quality raw materialsMishandling raw materialsChange in formulation of productChange in the process of productCross-contaminationInadequate cleaningInadequate maintenanceAddition of the wrong ingredient

Cross- Contamination

Hands- Raw food- Ready to eat food

Food contact surfaces

Cleaning Cloths, sponges

Touch or drip fluids

Your Challenge To Prevent Outbreaks:

Number of foods at risk

Multiple chances of food to be contaminated

Types of Customers - Children, Elderly

Shortage of trained EmployeesHigh Employee turn-over

SO LET US MAKE A BEGINNING

G. Modified Crops

ArtificialQuality System

Food Safety

Restricted Substances

Wrong Mark/Label

Package Failure

Pesticides

Unhygienic conditions

Process Out-of Control

Superficial Quality Checks

Transportation Damage

Lack of Awareness

StorageDamage

RISK

Chemical Fertilizers

HACCPHazard Analysis and Critical Control Point

Is HACCP ….

H - Hard!A - Agonizing!C - Confusing!C - Complicated!P - Paper work!

It IsNOT

HACCP stands for

H - Hazard A - Analysis C - Critical C - Control P - Points

HACCP

A system for Food - Safety Control

Benefits of HACCP

Systematic approach to Food SafetyProactive and Preventive management systemComplements and strengthens the QMSInternationally recognizedFewer rejectsCost EffectivenessIncreased confidence / customer satisfactionRisk Management ToolBrand ProtectionImproves Team work and motivationRegulatory Requirements

HACCP ISNot a zero-risk system, it is designed to minimize the risk of food-safety hazards.

A management tool used to protect the food supply chain and production process against microbiological, chemical and other physical hazards contamination.

Origin of HACCP

Pioneered in the 1960s.

First used when foods were developed for space program.

Adopted by many food processors and the U.S. Government.

Hazard

A biological, chemical or physical property that may cause the food to be unsafe for consumption

BASIC REQUIREMENTS FOR HACCP SYSTEM

HACCP Identifies Hazards

Biological

Chemical

Physical

Bacteria may be :

Pathogenic (Diseases)

Toxicogenic(Food Poisoning)

To GrowBacteria Need F A T T O M

Food (Nutrients)Acidity (pH >4.6)Temperature (4-60 deg C)Time (cell double every 20 minutes)Oxygen (aerobes + , anaerobes -)Moisture (Aw >0.85)

Temperature

Bacteria which cause food poisoningprefer to live at human body temperaturewhich is 37°C.

TEMPERATURE

4 °C 65 °C Danger Zone

0 0.2 0.3 0.4

0.5

0.8 0.9 1.0

Water

Meat/Poultry

Soft Cheese

0.60.7

DriedNoodles

JamsJellies

WATER ACTIVITY (Aw)

Potentially Hazardous FoodsAw > 0.85

15

7

9 14

Water

Bananas

Limes,Lemons

Commercial Mayonnaise

pH : Bacteria do notgrow well at a pH < 4.6

pH Scale

HACCP Training

BINARY FISSION

GIVEN IDEALCONDITION BACTERIA ARE ABLE TO DIVIDE INTO TWO EVERY

10-20 MINUTES

1 Bacteria Becomes7 hours 20 Lakhs , 8 hours 1 Crore70 Lakhs ,9 hours 13 Crores

Looks Impossible , But True, See How

671088645204096Four Hours335544325002048220

134217728Nine Hours8192260

16777216Eight Hours10242008388608460512Three Hours41943044402561602097152Seven Hours128140104857640064Two Hours52428838032100262144Six Hours16801310723408One Hour6553632044032768Five Hours2201638428010

NumbersMinutesNumberMinutes

No.of Cells

Time

Lag

Log

Stationary

Decline

The PHASES of Bacterial Growth

Virus

Hepatitis A and ENorwalk Virus GroupRotavirus

VIRUSContaminate food through

poor personal hygiene

contaminated water or through shellfish

Can cause serious illness such as hepatitis A

PARASITES AND FUNGI

Parasites are micro-organisms that need a host to survive

Can be killed by thorough cooking or freezing

Molds - usually microscopic - colonies can been seen as fuzzy growths

Yeasts - need sugar and moisture - appears as bubbles or slime

TOXINSFISH TOXINS

Puffer fish, moray eels, and freshwater minnows contain natural toxins

Amberjack, barracuda and large snappers can carry Ciguatoxin (Ciguatera)

PLANT TOXINS

SOME MUSHROOMS

JIMSON WEED AND WATER HEMLOCK

JELLY MADE FROM APRICOT KERNELS

COOKING OR FREEZING DO NOT DESTROY ALL PLANT TOXINS

These are chemicals in the food which will cause:

Illness if ingested

Poisoning

Accumulate in body tissue

Long term health disorders

CHEMICAL HAZARDS

CHEMICAL HAZARDS

Pesticides

Food additives and preservatives

Cleaning and sanitizing chemicals

Toxic metals

Lubricants used on equipment

Personal care products

Paints

The following table lists some of the different types of chemicals hazards:

Mold Toxins

Aflatoxin

Histamines

Agricultural Chemicals PesticidesAntibiotics Insecticides

Food Additives

Preservatives (Nitrites)

Flavour Enhances

Colour Additives

Detergents

Lubricants

CHEMICAL HAZARDS

Unintentionally or incidentally Added chemicals:

Agricultural Chemicals (e.g.., pesticides, fungicides, herbicides, fertilizers, antibiotics, and growth hormones)

Prohibited substancesToxic elements ( lead, Zinc, arsenic, mercury, cyanide)Secondary Direct and Indirect

- Plant Chemicals (e.g., lubricants, cleaning compounds ,sanitizers, paint)

Physical Hazards

Any potentially harmful extraneous matter not normally found in food

These are foreign objects which may cause:

Trauma

Injury

Illness

The customer to think poorly of your products

PHYSICAL HAZARDS

Metal from machines

Hair in food

Glass pieces in ice

Plastic pieces from stocking crates

Wood from shipping crates

Insect droppings in rice, wheat

PHYSICAL HAZARDS

The foreign materials most commonly found in foods are:

Material Likely Sources

WoodGlassStones (Pits)PlasticMetalBoneInsectsHairJewelry

Utensils, PalletsLamps, BottlesDried Fruits, VegetablesPackagingMachineryMeatEverywhereStaffStaff

PHYSICAL HAZARDS

QUALITY HAZARDS

Is a term used to encompass environmental Hazards,animal welfare hazards, occupational and safety

hazards, as well as failure to meet customer requirements.

Quality hazards do not

cause sicknessto the consumer

But sickens the company

Examples of Quality Hazards:Wrong protein levels in wheatOranges with blemishesPotatoes of the wrong sizeBread that has been over bakedA meal in a restaurant that has been poorly presentedThe bottom falling out of a meat pieProduct specifications not met, i.e., size, shape, texture,smell

Pre-requisites

GMP - Good Manufacturing Practices

SSOP - Sanitation Standard Operating Procedure

HACCP - Hazard Analysis and Critical Control Point

PRE-REQUISITES

GMP is a Sound Foundation for Food SafetyGMP provides independent certification and verification that the basic pre-requisite GMP necessary for an effective HACCP food safety program are being followed.GMPs are minimum common sense sanitary and processing requirements applicable to all food processing establishments. They provide the basic foundation for the development of an effective food safety & quality management system.Many food industry sectors have implemented GMP for food processing as the foundation upon which they have developed and implemented other food safety & quality management systems, such as HACCP, SQF 2000cm and/or ISO 9000.

Food Hygiene TrainingGMP or HCE

HACCP

Good Manufacturing Practices

Personal Hygiene

Building and Facilities

Plant and Ground

Sanitary Operations

Sanitary Facilities

and Controls

Good Manufacturing Practices

Equipment and Utensils

Process and Controls

Warehousing and Distribution

GMP COMPONENTS

Buildings and facilitiesEquipment and utensilsProduction and process controls

BUILDING EXTERIOR:

Design, Floor, Windows, Animals, Glass, Drainage.

Lighting

Air Quality, Ventilation, Air Filters, Dust Collectors,

Positive / Negative Pressures

Waste, Drains, Sewage, Waste Collectors

A big no to this

BAD-House keeping

A big no to this

BAD-Broken tiles-accumulate waste

BAD-Roof leaking and causing untidiness

BAD-Open door leads to pests

Is it dangerous for products ?????

Good and Bad

BAD-Steam leakage-Energy loss

BAD-GMP

GOOD-Preventive practices

Is it Right way to keep clean uniforms

Is it right way to keep

Aisa Kyo Hota Hai ???????

BAD-Storage at the side of wall

BAD Nail coming out & Broken

GOOD-Chemical Storage Practices

Is it right ??????

Kya Yeh Sahi Hai ????

Kya Yeh Sahi Hai ????

Requirement for refuse storage

Lids must be tight and well fittingThey must be emptied and cleaned regularly

√

Insect - o- cutor

Should be always on while work is in progress

Rat Station -Instructions

Rat Trap –Keep this ok always

This may lead to pest breading

PERSONAL HYGIENE

Why is Good Hygiene Important to Food Safety?

All of us carry disease-causing bacteria on or in

our bodies. These bacteria can be carried to

food, where they will make a customer or a co-

worker sick. By staying healthy and keeping

clean, you can prevent an outbreak of foodborne

illness.

It is all about you!

POOR PERSONAL HYGIENE HABITSOFTEN LEAD TO

FOOD SAFETY PROBLEMS

Employees must be trained on personal hygiene habits

Written instructions on personal hygiene are required

Rules must be : Established, Implemented and Enforced

WASH HANDS

• After visiting the w.c.• On entering a food room• After combing hair • After eating, smoking,

Blowing nose• After handling waste• After handling raw food

HAND WASHING PROCEDURE

Wash hands with hot waterUse soap and a nail brushClean nails and between fingersRinse with waterDry Disinfect (with sanitizer)

THIS PHOTOGRAPH SHOWS MICROBIAL GROWTH ON AGAR 24 HOURS AFTER BEING TOUCHED BY

A WORKER WITH DIRTY HANDS.

THIS IS THE RESULT OF WASHING WITH SOAP AND WATER FOR ONLY TWENTY

SECONDS.

WASHING WITH SOAP AND WATER FOR AN ADDITIONAL TWENTY SECONDS (40 SECONDS TOTAL) RESULTS IN EVEN MORE BACTERIA BEING REMOVED FROM THE FINGERS.

THIS IS THE RESULT OF WASHING WITH SOAP AND WATER FOR FORTY (40) SECONDSFOLLOWED BY THE USE OF A HAND SANITIZER.HARDLY ANY BACTERIA

REMAIN ON THE FINGERS.

HAIR THAT GETS INTO FOOD IS NOT ONLY UNSIGHTLY AND UNAPPETIZING, IT IS LOADED WITH BACTERIA. NOTE THAT EACH STRAND OF HAIR ON THE PLATE IS COVERED WITH BACTERIA.

Jewellery

• Traps bacteria• Chemical reaction with foods• May drop into food

√

√ √

√

√

SMOKING

Is illegal in food rooms:

1. Transfer bacteria via saliva 2. Causes coughing 3. Contaminates work surfaces4. Produces an unpleasant environment

PROTECTIVE CLOTHING MUST BE

Clean

Washable

Light colored

No buttons

No pockets

Employee Health

Employees should NEVER work with food if suffering from any of the following conditions:

FeverDiarrheaUpset StomachSore throatCoughs/coldsDizziness

Such Employees must stay at home until well !

Cleaning EquipmentMonitoring SSOPsRecords to be maintained

Personnel practicesEquipment practicesPlant facilitiesWarehouse practicesEquipment & operation design

SANITATION CONTROL:

SANITARY FACILITIES

Hand washing - soap, sanitizer, procedures, signboards

Equipment cleaning area

Water quality, treatment, testing, records

Storage of product - humidity control, pests

Sanitation Standard Operating Procedures (SSOP)

Safety of waterCondition and cleanliness of food-contact surfacesPrevention of cross-contaminationMaintenance of hand-washing, hand-sanitizing and toilet facilities

STOP CROSS CONTAMINATION

Keep raw food and cooked food separateUse colored coded boards &knives

To Stop cross contamination

• Keep all items separate and covered• Use separate stacking boards & place• Keep the contact surfaces clean

THE CHAIN OF INFECTIONBACTERIA

CONTAMINATION

FOOD

MULTIPLICATION

ILLNESS

BREAKING THE FOOD POISONING CHAIN

• PROTECT FOOD FROM CONTAMINATION

• PREVENT MULTIPLICATION

• DESTROY THE BACTERIA

CONTAMINATION

MULTIPLICATION

BACTERIA

PROTECT FOOD FROM CONTAMINATION

Cover food

Avoid handling food

Separate raw and cooked food

Eliminate animals and insects

Practice personal hygiene

Careful refuse disposal

Keep clean

Sanitation Standard Operating Procedures (SSOP)

Protection from adulterantsLabeling, storage and use of toxic compoundsEmployee healthExclusion of pests

If Sanitation is in Place, it results in developing anEffective HACCP Plan

GMP & SSOP are to be effectively controlled. All effort to be made to Focus on hazards associated with Food.

Exception: Although CIP (Clean-In-Place) is a sanitation activity, could be taken as CCP

Pest Control Programs to be covered by SSOP,and not as CCP or a HACCP Plan.

Prerequisite Programs : Others

Steps or procedures that control the in-plant environmental conditions that provide a foundation for safe food production. Examples include:

Training

Recall Programs & Traceability

Preventive maintenance

Product identification program and coding.

Traceability

Identify a unique batch ofProduct

Raw material used in production

Then followThat batch

and Each individual unit comprising the batch

Through theProduction

And/or distribution process ,to immediate consumer

Traceability

All Food Business should:

Define the scope of their traceability system

Document their traceability system

Set up mechanisms to periodically review their traceability system

Test their traceability system when testing their recall procedures

Traceability

Supplier Traceability

Traceability of suppliers and their goods entering a

business

Process Traceability

Traceability of food stuffs through a business

Customer Traceability

Traceability of Food stuffs to immediate customer

Product recall

Recall is

Removal of unsafe food from distribution chain

Recall extends to

Food sold to consumers

Recall involves

Communication with consumers

A recall should be initiated when a foodstuff is identified as unsafe, is a potential risk to public and has been distributed to the consumer

Product Recall

Object is to Protect public health by informing consumers of the presence on the market of

a potentially hazardous foodstuff

And by facilitating the efficient, rapid identification

Removal of unsafe foodstuffs from

The distribution chain

Thus ensuring that the unsafe foodstuffs are Either destroyed or

Rendered safe

WITHDRAWL

This is removal of an unsafe foodstuff from the

distribution chain but dose not extend to food sold

to the consumer

A withdrawal should be initiated when a food stuff

is identified as unsafe, is a potential risk to public

health but it can be demonstrated that the unsafe

foodstuff remains wholly in the distribution chain

and has not reached the consumer

Stages of Product Recall Procedures

Development of a product recall policy

Development of a product recall plan

Testing of a product recall plan

Notification and initiation of a product recall

Management of a product recall

Closing a product recall

Review of a product recall plan

Amendment of the product recall plan

Recall plan-role and responsibilities

Owner /CEORecall Coordinator

Distribution

Product &QA

Consumer affairs

Accounting

Legal Counsel

Public Relations

Technical

Marketing

Regional Sales manager

1.Stop all distribution-arrange for return.2.Prepare inventory and distribution status of product.

1.Preapre batch identification.2.Halt production of product if related problem.3.Investigatefor cause of problem ,check all records.

1.Prepare response for consumers.2.Answer all consumer enquiries.

1.Set up stock reconciliation system to determine cost of recall.

1.Handle legal complications.

1.Handle press releases-All media.

1.Obtain batch identification and samples.2. Obtain product analysis to determine if pick-up or destruction necessary.3.Consult with regulatory agencies if a recall is required.

1.Notify sales manager and brokers.2.Arrange for pick-up at retail levels.3.Arrange for proper credit to be given.

1.Aid contacting customers.2.Assist in product pick-up and delivery of credit notes.

Product Recall Decision Tree

Product distributed to consumers via caterers

Health Hazard confirmed

Collate all traceability information

Convene recall team

Conduct documented through risk assessment

Report received – initial details taken

Suspend distribution of product

Invoke recall plan

Potential health hazard

QA Manager-Make preliminary risk assessment

Notify Quality Assurance Manager or other

Complaint or notification of product problem

No health hazard

Handle as complaintOr Quality Recall Notify Co. Executives

Notify Regulatory Authorities

Initiate product analysis where necessary

No health Hazard

Handle as complaint or quality recall

Product not distributed to consumers

Collate all product/ prod. Info.

Product distributed to consumers

CARRY OUT RECALL CARRY OUT WITHDRAWL

Sample Trade Notification

URGENT

Product Recall (or withdrawal )

Company Name ________________________________

Product Name ________________________________

Product Details ________________________________

Batch Identification ________________________________

‘Use by' or ‘BB date’ ________________________________

Reason for the Recall

___________________________________________________

___________________________________________________

Action Required

___________________________________________________

___________________________________________________

Contact Details ___________________________________

Alternative

Contact Details ____________________________________

Product Recall NoticeWARNINGFood Product RecallCompany nameProduct Name /DescriptionPack SizeBatch Identification

Product Photograph

or illustration

Details of what is wrong with the product

Action the consumer should take

We apologies for any inconvenience

Company address and contact details

THE HACCP APPROACH

The Codex Guidelines identify 12 steps for the implementation of the 7 HACCP Principles.

CODEX – 12 STEPS

HACCP Implementation as per Codex Guidelines: 12 steps

1. Formation of HACCP Team 2. Product Description3. Intended Use of the Product and Customer4. Process Flow Diagram5. On-Site Verification of the Process Flow6. Conduct Hazard Analysis and Identify Preventive 7. Identify CCP8. Set Critical Limits9. Monitoring of critical limits associated with each CCP10. Establish Corrective Actions when the CL deviate11. Establish Verification Procedures12. Record Keeping Procedures

Developing a HACCP Program

To set up a foundation the following basics are required

5 stepsAssemble HACCP teamDescribe the productIdentify Intended UseDevelop a flow diagramOn site verification of flow diagram

Specialist

Others

Specialist

Team Member

Team Member

Team Member

Team Leader

KNOWLEDGE/ SKILLS and Experience (Years)

POSITION WITH COMPANY

NAMEFUNCTION IN TEAM

HACCP TEAM

Product Description

------months from the date of mfd/ pkg.Shelf Life

Consume as such –preferred serve chilledCustomer Preparation

Diet - Contains aspartame, not suitable for phenylketouranics ,not for children below 12 years of age

Special Labeling

By VehicleDistribution Method

Ambient temp, cool and dry place away from direct sunlight

Storage conditions

---- colored plastic crates with ----pockets & printedCFB boxes of ---- ply ,printed/plain

Packaging -Shipping

Glass/ Food Grade Pet bottle with PVC blend crown / pp PVC cap in 200,300,600,2000ml

Packaging - Primary

Low pH, Anaerobic condition by CarbonationMethod of Preservation

---------colored/transparent, clear liquid, without suspended matter, sweetened and biting

End Product Characteristic

Write IngredientsComposition

Sweetened Carbonated beverage-brand/diet/waterProduct Name

STEP 3: Intended use

For general people

For elderly

For infants

For immunologicaly challenged –allergic

milk, pea nut, tree nut (ex. walnut), sesame, egg,

fish, shell fish , wheat, soy

Symptoms of Allergy

Symptoms typically appear within minutes to two hours after a person has eaten the food to which he or she is allergic.

Tingling sensation in the mouth

Swelling of the tongue and throat

Difficulty in breathing

Hives

Vomiting

Abdominal cramps

Diarrhea

Drop in blood pressure

Loss of consciousness, and death.

•

Step 5 :Example of Basic Flow DiagramReceiving of Green Leaf

Trailer Unloading

Trough Loading/Spreading

Withering

Rolling

Addition of Media Packing

Conditioning

Distribution

STEP 5 : Onsite verification of the flow diagram

A Step Missed

Hazards missed

Potential safety risk

Seven Principles of HACCP

1. List all potential hazards , Conduct Hazard Analysis, Identifypreventive measures.

2. Determine Critical Control Points (CCP)3. Establish Critical Limits for each CCP4. Establish a monitoring system for each CCP.5. Establish corrective Action for deviation that may occur. 6. Establish Verification Procedures.7. Establish Record-keeping and Documentation.

Principle 1:

Conduct Hazard Analysis. Prepare a list of steps in the process where significant hazards occur and describe the preventive measures.

Hazards Limited to food safety

HACCP Team will analyzeEach hazard - Risk, Likelihood of occurrence and Severity of hazard to be analyzed. Experience,Technical information.Consider factors beyond immediate controlDecide which hazards are significantSafety concerns Vs. Quality concerns

Hazard Analysis:

a. Brainstorming - List of potential hazards at each step (RM to Final) not confined to likelihood of occurrence

b. Risk Assessment - Focus on reasonably likely to occur hazards (Health risk to consumers)

Part A. HAZARD IDENTIFICATIONList All Potential Hazards

Sources of Potential Hazards

Raw materials

Plant and equipment design

Intrinsic factors in the product or raw materials

Process design (Procedures)

Personnel (Staff / Visitors)

Storage and distribution

Examples of raw materials are:

Food ingredients (chilled, frozen, dry, liquid).

Water (used in formulation or to wash or rinse products).

Cleaning chemicals.

Packaging.

Pesticides, insecticides

Part B. HAZARD EVALUATION

Conduct Hazard Analysis and Determine the Significance of the identified Hazards

Determine Likelihood of occurrence

Determine Severity/ Influence of PrerequisitePrograms Determine Significance

Method 1

Method 2

A significant hazard has the potential to cause serious illness or injury when the food-stuff is consumed.

Determine Significance of Hazards - Method 1

In this first method, the likelihood of a hazard ocuring

may be simply rated as high (H) or low (L)

The severity of a hazard ocurring is also rated as high

(H) or low (L)

Based on the above, significance of the hazard is then

determined

Determine Significance of Hazards -Method 2 Matrix Method for Food Safety

Severity (consequences) Likelihood (frequency)

1. Fatality A. Common Repeating

2. Serious Sickness B. Known to occur

3. Product Recall C. Could occur (published)

4. Customer Complaint D. Not expected to occur

5. Not Significant E. Practically impossible

Hazard Significance Matrix for Food Safety

FREQUENCY A B C D E

CONSEQUENCE 1 1 2 4 7 11

2 3 5 8 12 16 3 6 9 13 17 20 4 10 14 18 21 23 5 15 19 22 24 25

Factor FactorSeverity ( S )Likelihood ( L )

1Once in 3 years Lethal -Death

2 Organ Removal 5

3

6

4

5

4

6

Once in a year

Monthly

Weekly

Daily

Once in 6 months

Presence notPreferred

Ill for a month

Ill for a week

Minor healthinjury

1

3

2

L X S = Risk Factor

Above 6 RF = Significant Hazard

FOOD SAFETY DESCRIPTORS

FOOD SAFETY

CCP: Critical Control Point

Contorl measure(s) that must be in place to address food safety of significance

CP: Control Point Conrol measure (s) that are in place to address food safety hazards of lesser significance

HAZARD ANALYSIS WORK SHEET

Hazard Analysis Work Sheet

(6)What

preventive measures

can be applied to prevent

the significant Hazard?

Quality

Physical

Chemical

BiologicalWrite Process

Step No. & Name

(7) Is this step Critical

Control Point /CQP

Yes / No

(5)Justify your decision for column 3

(4)Indicate

Likely hood & Severity of Hazard

H,M,L

(3)Are any Potential

Food Safety Hazard

Significant

(2)Identify

PotentialHazard,

Controlled or

enhanced at this step

(1)Ingredient/

Process Step

Product Name: Product Description:

Firm Address: Method of storage and Distribution:

Intended Use and Customer:

Part C.

IDENTIFY CONTROL MEASURES

Identify Control Measures

Control Measures are any factors, actions and

activities that can be used to control an

identified food safety or quality hazard.

Control measures must eliminate, control or

reduce the effect of a hazard to an acceptable

level

CONTROL MEASURES for Biological hazards

Pasteurization - application of time/temperature

Fermentation

Acidification - pH control

Pickling - addition of salt

Drying - Aw reduction

Freezing/cooling

Training to prevent cross contamination

Control Measures for Chemical Hazards

Supplier Quality Assurance ProgramsCertificate of Analysis - signed and meet specification Sanitation Program - approved food grade chemicals, visual inspectionsPest Management Program - approved pesticidesAntibiotic TestingDesignated with-holding period for crop control chemicalsCorrect Labels - for products containing allergens

CONTROL MEASURES for Physical Hazards

Sieves - use nitex (not metal wire)ScreensMagnetsFiltersMetal DetectorsGlass Control PolicyGood Manufacturing Practices - personal hygiene proceduresUse of Plastic (not Wooden) Pallets.

FOOD SAFETY HAZARDS ASSOCIATED WITH THE BEVERAGE INDUSTRY

PRINCIPAL RAW MATERIALS/ INGREDIENTS USED FOR MANUFACTURE OF NON ALCOHOLIC SOFT DRINKS.

WATERAROMATIC SUBSTANCESSWEETENERSCARBON DIOXIDEACIDSCOLOURING MATTERPRESERVATIVESANTIOXIDANTSEMULSIFYING/ STABILIZING/ THICKENING AGENTS

WATER

HAZARDSMICROBIOLOGICAL - PATHOGENS, NATURAL

SAPROPHYTES, PROTOZOA ETC

CHEMICAL- PESTISIDES, HEVAY METALS, OTHER INORGANIC COMPOUNDS

PHYSICAL SUSPENDED MUD, ODOUR, ORGANIC MATTERSEVERITY/ LIKELYHOOD

COMMONLY OCCURING, CAN CAUSE SERIOUS DAMAGETO HEALTH

PREVENTIONTREATMENT OF WATER BY UV, RO, CARBON FILTER ETC

PROPER SELECTION OF SOURCE

CAFFEINEHazardous when used in overdose with effects like

restlessness, nervousness, insomnia, diuresis etcSYNTHETIC AROMATIC SUBSTANCE

Presence of Heavy Metals , Impurities etcLIKELYHOOD/ SEVERITY

Medium PREVENTION

Regulated application, COA from suppliers etc

ACIDS

CITRIC ACID, MALIC ACID, PHOSPHORIC ACIDHAZARDS

Excess use of Phosphoric Acid causes loss of Calcium from body, Reduces absorption of Mineral.

LIKELYHOOD/ SEVERITYMedium

PREVENTIONRegulated application

PRESERVATIVES

SODIUM BENZOATE, POTASSIUM SORBATE, SULPHUR DIOXIDE

HAZARDSSodium Benzoate dosage above 1.8g/Kg is toxic.

LIKELYHOOD/ SEVERITYMedium

PREVENTIONRegulated Application

SWEETNERS

SUGAR, SACCHARIN, ASPERTAMEHAZARDS

Pesticides in Sugar, Moisture, Odour in Sugar after Acidification, Over usage of Aspartame causes cellular death of Neurons, toxic for PKU.

LIKELYHOOD/ SEVERITYMedium

PREVENTIONRaw Material (Sugar) inspection and testing,

Source Control and monitoring, regulated application of other sweeteners, proper labeling.

EMULSIFIERS, STABILIZERS, THICKENING AGENTS

PECTINS, ALGINATES, CARRAGENEN ,SYNTHETIC MATERIALS

HAZARDSImpurities, Character Hazards

LIKELYHOOD/ SEVERITYMedium

PREVENTIONRaw Material Inspection, Testing, COA

CO2

HAZARDSImpurities viz. Sulphur Compounds

LIKELYHOOD/ SEVERITYMedium

PREVENTIONRaw material testing, COA from Supplier

Principle 2: Identification of Critical Control Points

Objective

The definition of Critical Control Point(CCP)The relationship between a significant hazard and a CCPA CCP may change for product formulations and processing linesThe use of a decision tree to select a CCP Examples of CCPs.

Definition

Critical Control Point:

A point, step or a procedure at which control can be applied and a food-safety hazard can be prevented,

eliminated or reduced to acceptable levels.

ForEach

Hazard

Q. 2 Do Preventive Measures exist ?

Is Control atthis step necessary for

Food Safety

Q. 3 Is the step specifically designed to eliminate or reduce the likely occurrence of a hazard to an

acceptable level ?

Q. 4 Could contamination with identified hazard(s) occur in excess of acceptable level(s) or could they

increase to an unacceptable level ?

Q. 5 Will a subsequent step eliminate or reduce the likely occurrence of the identified hazard to an

acceptable level ?

Yes

Yes

No

No

Question forces consideration of

growth or contamination

Focuses team on realistic end use

of product

Highlights importance of

labelling cooking & storage

Thought required about processing,

handling etcC C P

C C PNot a C C P

Not a C C P

Not a C C P

No

Modify step, process

or product

Yes No

Yes

Yes No

Q 1 Is here a significant hazard at this process step ?

Not a CCP

No

HACCP DECISSION

TREE

Definition

Control PointAny point, step or a procedure at which

biological, physical or chemical factors can be controlled.

CCPs Vs. Control Points

CCPs are product and Process-Specific

Principle 3 : Establish Critical Limits

Objective:

How to define Critical LimitHow to set Critical Limit for a CCPHow to find sources of Critical Limit InformationHow to determine the relationship between

Critical Limits and Operating Limits

Definition :

Critical Limit: A criterion that must be met for each preventive measure associated with a CCP.

Boundaries to produce safe food.

Examples of Critical Limits:

Hazard CCP Critical LimitMicro risk Pasteurization 81+/- 2 c for 15 sec. Due to yeast of Sugar Contact time 30 minutes

Sulphur & Receiving CO2 99.9% Purity Sulphur Inspection COA -SUPPLIER Compounds T. Sulphur < 0.2ppm

Operating Limits:Criteria that are more stringent than critical limits and that are used by an operator to reduce the risk of deviation.

Process Adjustment :

An action taken by the firm to bring the process back within operating limits.

Principle 4:

Establish CCP monitoring requirements. Establish procedures for using the results of

monitoring to adjust the process and maintain control.

Objective:How monitoring is defined Why monitoring is neededHow to design a monitoring systemWhat methods and equipment are used for monitoring

critical limitsHow often monitoring should be performedWho should monitor

Definition

Monitor

To conduct a planned sequence of observations or measurements to assess whether a CCP is under control

and to to produce an accurate record for future use in verification.

MONITORINGPurpose of Monitoring

To track the operation of the process and enable the identification of trends toward a critical limit that may trigger process adjustment.

To identify when there is a loss of control ( a deviation occurs at a CCP ), and

To provide written documentation of the process control system.

How Critical Limits and Preventive Measures will be Monitored

MONITORINGWHAT: usually a measurement or observation to

assess if the CCP is operating within the critical limit

HOW: usually physical or chemical measurements(for quantitative critical limits) or observations (for qualitative critical limits). Needs to be real-time and accurate.

WHEN (frequency): can be continuous or intermittent

WHO: someone trained to perform the specific

WHERE: At what stage or step it is to be moniteredmonitoring activity.

Principle 5 : Corrective Actions

Objective

The definition of Corrective ActionsProcedure for Corrective ActionsRecord-keeping requirements for corrective

actions

When a deviation from a critical limit occurs, a corrective action must be

taken.

Corrective Action :

Procedures to be followed when a deviation or failure to meet a critical limit occurs.

Corrective Action Components :

To correct and eliminate the cause of the deviation and restore process control.

To identify the product that was produced during theprocess deviation and determine its disposition.

Principle 6 : Verification Procedures

Objective :

How to define Verification

What functions are part of HACCP Plan verification

How to define validation

What functions are part of validation

Establish procedures to verify that the HACCP system is working correctly.

Verification

The use of methods, procedures or tests, in addition to those used in monitoring, to determine

if the HACCP system is in compliance with the HACCP plan and/ or whether the plan needs

modification and revalidation.

Trust What You Verify

Verification provides a level of confidence that the HACCP plan is based on solid scientific

principles, is adequate to control the hazards associated with the product and the process,

and is being followed.

Verification activities for CCPs

Calibration

Calibration record-review

Targeted sampling and testing

CCP record-review

HACCP SystemVerification Frequency

Annually

Occurrence of a system failure,or

Significant change in product or process

Audit Verification activities of the HACCP system :

Check the accuracy of the product description and Flow Chart

Check that CCPs are monitored as required by theHACCP plan

Check that the processes are operating within established critical limits

Check that records are completed accurately and at the time intervals required.

Principle 7: Record-Keeping Procedures

Objective :

What kinds of records are needed in a HACCP system

When to record monitoring information

How computerized records can be used

How to conduct a record-review

Establish effective record-keeping procedures that document the HACCP system

Four kinds of records are kept as part of the HACCP system:

1. HACCP plan and support documentation used in

developing the plan

2. Records of CCP monitoring

3. Records of corrective action

4. Records of verification activities.

All HACCP monitoring records should be on forms that contain the following information :

Form titleFirm nameTime and dateProduct identification (including product type, package size, processing line and product code, where applicable)

Actual observation or measurementCritical LimitsOperator’s signature or initialsReviewer’s signature or initialsDate of review.

OTHER AREAS OF CONCERN

Presence of yeast in sugar – Pasteurization ,Raw Material Control,

Atmosphere , Sanitation control

Activated carbon carry over to product –RO after carbon filter

Caustic carry over to product – GMP-pH testing of wash water

Glass pieces carry over to product – GMP-Glass policy monitoring

Inadequate cleaning of bottles – SSOP-periodic monitoring

Foreign material carry over to product – Identification of source

High alkalinity of water leads to poor product quality – Proper

source selection, use of buffers.

THANK YOUSGS India Pvt. Ltd.,

SGS HouseA-77, Road No.16

Wagle Industrial Estate, Thane. 400 604Suhas.bedekar@sgs.com