GOOD MANUFACTURING PRACTICES Training about our Food Safety

GOOD MANUFACTURING PRACTICES Training about our Food Safety Plan Good Management Practices Dec-07

HACCP ACRONYM H A C C P GOOD MANUFACTURING PRACTICES azzard nalysis ritical ontrol oint Good Management Practices Dec-07 2

HISTORY OF THE HACCP SYSTEM GOOD MANUFACTURING PRACTICES Ø HACCP was developed in the 1960’s when NASA asked Pillsbury to design and manufacture the first food for space flights Ø 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 Good Management Practices Dec-07 3

WHAT IS HACCP? GOOD MANUFACTURING PRACTICES Ø 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. Ø With HACCP the food processor systematically: Ø Identifies potential Analysis). food safety hazards (Hazard Ø 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) Good Management Practices Dec-07 4

KEY CONCEPTS OF A HACCP PLAN GOOD MANUFACTURING PRACTICES Ø Good Manufacturing Practices (GMPs) Ø Standard Operating Procedures (SOPs) Good Management Practices Dec-07 5

SOP’s ALLOW YOU TO: GOOD MANUFACTURING PRACTICES 1. SAY what you do 2. DO what you say 3. PROVE it Good Management Practices Dec-07 6

WHAT ARE CCPs (Critical Control Points)? GOOD MANUFACTURING PRACTICES Ø A CCP is a key step where hazards can be prevented, eliminated or reduced to an acceptable level. Good Management Practices Dec-07 7

THE SUCCESS OF HACCP AND THE SEVEN PRINCIPLES GOOD MANUFACTURING PRACTICES 1. Identify Hazards 2. Determine Critical Control Points (CCPs) 3. Establish Critical Limits 4. Establish Monitoring Procedures 5. Establish Corrective Action Procedures 6. Establish Verification Procedures 7. Establish Record Keeping Good Management Practices Dec-07 8

PREREQUISITE PROGRAMS GOOD MANUFACTURING PRACTICES A. Premises (including water supply) B. Transportation, Receiving and Storage C. Equipment Design, Installation and Maintenance D. Personnel Training E. Sanitation & Pest Control F. Recall Good Management Practices Dec-07 9

GOOD MANUFACTURING PRACTICES (GMPs) GOOD MANUFACTURING PRACTICES Ø 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) Good Management Practices Dec-07 10

GMPs ARE: GOOD MANUFACTURING PRACTICES Ø Preventative measures to ensure food safety Ø Based on practical experience over a long period of time Ø The foundation on which to build a HACCP program Good Management Practices Dec-07 11

STANDARD OPERATING PROCEDURES (SOP’s) GOOD MANUFACTURING PRACTICES Ø The purpose and frequency of doing a task Ø Who will do the task Ø A description of the procedure to be performed Ø What paperwork is to be completed (documentation) Ø The method by which you show that task is satisfactorily completed Ø And the corrective actions to be taken of the task is performed incorrectly Good Management Practices Dec-07 12

CORRECTIVE ACTION REQUEST Ø A CAR must be completed for each deviation from the SOP Ø CAR Form Ø CAR Instructions GOOD MANUFACTURING PRACTICES Ø State deviation Ø Use objective Evidence Ø Develop an action plan to prevent deviation reoccurrence Ø Set a deadline Ø Verify that the action plan has been effective Good Management Practices Dec-07 13

PREREQUISITE PROGRAM: PREMISES GOOD MANUFACTURING PRACTICES Ø Building Exterior Ø Building Interior: Design, Construction, Lighting, Ventilation, Waste Disposal, Inedible Areas Ø Sanitation Facilities: Employee Facilities, Equipment Cleaning & Sanitizing Facilities Ø Water/Ice Quality and Supply Good Management Practices Dec-07 14

PREREQUISITE PROGRAM: PREMISES GOOD MANUFACTURING PRACTICES Ø Premises SOP Ø Monitoring Procedure: part of internal audit procedures Good Management Practices Dec-07 15

PREREQUISITE PROGRAM: TRANSPORTATION, RECEIVING & STORAGE GOOD MANUFACTURING PRACTICES Ø Receiving: Food Carriers, Temperature Control, Approved Suppliers Ø Storage: Ingredient, Allergen, Finished Product and Chemical Storage Ø Transportation: Food Carriers, Temperature Control Good Management Practices Dec-07 16

PREREQUISITE PROGRAM: TRANSPORTATION, RECEIVING & STORAGE GOOD MANUFACTURING PRACTICES Ø Transportation Receiving and Storage SOP Ø Monitoring Procedures: check each shipment, Ø CAR: example Ø Allergen Program Ø Approved Suppliers Program Good Management Practices Dec-07 17

PREREQUISITE PROGRAM: EQUIPMENT GOOD MANUFACTURING PRACTICES Ø Equipment Design and Installation Ø Equipment Maintenance and Calibration Ø Equipment SOP Ø Temperature Monitoring Log Ø Thermometer Calibration Good Management Practices Dec-07 18

PREREQUISITE PROGRAM: PERSONNEL GOOD MANUFACTURING PRACTICES Ø Training: Hygiene and Technical Ø Hygiene and Health Requirements Ø Personnel SOP Ø Employee Sanitation SOP Ø Visitor Log Book Good Management Practices Dec-07 19

PREREQUISITE PROGRAMS: Sanitation & Pest Control GOOD MANUFACTURING PRACTICES Ø SANITATION Ø PEST CONTROL Ø SOP Ø PREOPS CHECKLIST Ø TRUCK CLEANING LOG Good Management Practices Dec-07 20

PREREQUISITE PROGRAM: RECALL GOOD MANUFACTURING PRACTICES Ø The Recall System Ø Complaints Log SOP Ø Recall Template Ø Recall Notice Ø Allergen Alert Notice Good Management Practices Dec-07 21

CRITICAL LIMITS GOOD MANUFACTURING PRACTICES Ø Is a value which separates acceptability from unacceptability Ø Critical Limits must meet or exceed government regulations Ø One or more critical limit must be met to ensure a CCP is controlling the hazard Good Management Practices Dec-07 22

CRITICAL LIMITS GOOD MANUFACTURING PRACTICES Ø Temperature / Time Ø p. H Ø Aw (available water) Ø Preservatives Ø Available chlorine Ø Sensory observations Good Management Practices Dec-07 23

SOURCES OF CRITICAL LIMITS GOOD MANUFACTURING PRACTICES Ø Regulatory Standards Ø Company Standards Ø Literature Surveys Ø Experimental Studies Ø Expert Advice Good Management Practices Dec-07 24

CRITICAL LIMITS GOOD MANUFACTURING PRACTICES Ø Individual Product Profiles Ø Process Control Sheet Good Management Practices Dec-07 25

PRODUCTION RECORDS GOOD MANUFACTURING PRACTICES Ø Using CIMS to record ingredients, batch processing and finished product information Good Management Practices Dec-07 26

IMPORTANCE OF VERIFICATION GOOD MANUFACTURING PRACTICES Ø Ensures that all major processing steps have been identified Ø Validates the assumptions made regarding the movement of employees and product Ø Works towards continual improvement of the GMP system Good Management Practices Dec-07 27

IMPORTANCE OF VERIFICATION GOOD MANUFACTURING PRACTICES Ø Internal Audit Template Ø Label Review Good Management Practices Dec-07 28