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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 [email protected]
