HACCP Food Safety Management Systems Auditing HACCP an

HACCP Food Safety Management Systems Auditing.

HACCP an Introduction Hazard Analysis Critical Control Point It’s a food safety system. 1969 NASA in collaboration with Pillsbury develop this system to prepare food for astronauts. It’s a joint venture of FAO/WHO Applications HACCP can be applied to all stages of a food supply chain Production Preparation Processing Packaging Distribution HACCP has become a household name in the food safety industry, and is now being referenced in many other industries including pharmaceuticals and cosmetics.

Objectives Ø Understand food industry auditing systems Ø Understand relate components of auditing systems Ø Understand how audits support food safety and food defense management objectives. Ø Identify potential areas for improvement

Why consider an audit? Ø Food Code - 2009 Recommendations of the United States Public Health Service, Food and Drug Administration Ø Federal , State, Local Regulatory Authority Requirements Ø Centers for Medicare and Medicaid Services Ø The Joint Commission Standards Formerly JACHO: Joint Commission on Accreditation of Healthcare Organizations

What is the value of an audit? Establishment Inspection Evaluation of current conditions and whether they are in compliance with desired standard conditions. Legal – regulatory requirements Self inspection – internal standards Establishment Audit Evaluation of the management systems and operation controls in place to ensure that desired or required operating conditions are met and maintained.

What is the structure of an audit? A contracted auditing company will evaluate operation conditions, policy and procedure. Audit evaluation criteria will be organized criteria into categories. Examples include: Nutrition – Health and Safety Quality Food Safety Programs and Training Receiving, Storage and Transport Pest Control Employee Practices Building and Equipment Conditions Food Security

Audit System Terms and Acronyms

Independent Auditing Firms: Paster Training, Inc. Eco. Sure Steritect Cook & Thurber QMI – Saiglobal Siliker NQA ABC ASI SGS SCS ETC… AIB – American Institute of Baking (1919) Commitment to audit standards that support and incorporate GFSI standards, Codex (HACCP), FDA & USDA GMP’s, GRP’s – Good Retail Practices.

Auditing System Foundation Prerequisite Programs HACCP – Hazard Analysis and Critical Control Point There are seven principles, developed by the National Advisory Committee on Microbiological Criteria for Foods, that serve as the foundation for a HACCP system. What are they?

Auditing System Foundation Prerequisite Programs 1. Construction and layout of buildings and associated utilities. 2. Layout of premises, including workspace and 3. employee facilities 4. Supplies of air, water, energy and other utilities 5. Suitability of equipment and its accessibility for cleaning, maintenance and preventive maintenance 6. Management of purchased materials 7. Measures for the prevention of cross contamination 8. Cleaning and sanitizing 9. Pest control 10. Personal hygiene

Auditing System Foundation How Does HACCP Work in Food Production? 1. Conduct a hazard analysis to identify potential hazards that could occur in the food production process. 2. Identify the critical control points (CCPs) -- those points in the process where the potential hazards could occur and can be prevented and/or controlled. 3. Establish critical limits for preventive measures associated with each CCP. A critical limit is a criterion that must be met for each CCP. Where appropriate, critical limits may reflect relevant regulatory requirements.

Auditing System Foundation How Does HACCP Work in Food Production? 4. Establish CCP monitoring requirements to ensure each CCP stays within its limit. Monitoring may require materials or devices to measure or otherwise evaluate the process at CCPs. 5. Establish corrective actions if monitoring determines a CCP is not within the established limits. In case a problem occurs, corrective actions must be in place to ensure no public health hazard occurs.

Auditing System Foundation How Does HACCP Work in Food Production? 6. Establish procedures for verifying that the HACCP system is working properly. Verification procedures may include reviewing the HACCP plan, CCP records, critical limits as well as conducting microbial sampling. Both plant personnel and auditors will conduct verification activities. 7. Establish effective recordkeeping procedures that document the HACCP system is working properly. Records should document CCP monitoring, verification activities and deviation records.

Quality Assurance Manager (Responsibilities) Maintenance of the HACCP based Food Safety Program Implementation of HACCP. Labeling compliance. Auditing suppliers Compliance with customers audits To train staff with issues relating to food safety and HACCP. Initiating non-conformances (quality related) and following it through with suppliers with corrective actions. Managing designated warehouses, pack room and blending areas for the continuous certification of HACCP.

Assistant QA Manager (Responsibilities) Checking of incoming raw and packaging materials and helping in all aspects of managing and improving quality and food safety throughout the supply chain functions such as procurement, receiving, inventory control, warehousing, distribution, pack room and blending operations. Maintaining and improving standards in various warehouses by coordinating and driving HACCP based Food Safety Program, Quality and Food safety Monitoring Schemes, Quality Training, Corrective and Preventative actions, and GMP standards in a Quality Facilitator Capacity. Attending to customer complaints and non conformances and following them through. Making decisions on Hold/Reject/Rework on Raw and Packaging Materials, Outsourced Products Increasing the GMP Scores Reducing NCRs Coordinating training across staff Providing support to customers and customer services Keeping documentation updated and implemented Ensuring products comply with the labeling laws

TRAING COURSE Campden BRI Members £ 725 Non– members £ 940

GFSI – Global Food Safety Institute Approved auditing schemes: The International Food Standard (IFS), based in Paris, Safe Quality Food (SQF) based in Arlington, USA The British Retail Consortium (BRC) based in London The Dutch Hazard Analysis Critical Control Points food safety system (Dutch HACCP) based in Apeldoorn. Submitted: Food Safety System Certification (FSSC) 22000

The Global Food Safety Initiative (GFSI) is a non-profit making foundation, created under Belgian law. The daily management is undertaken by CIES – The Food Business Forum. The GFSI Mission is to work on continuous improvement in food safety management systems to ensure confidence in the delivery of food to consumers.

The GFSI Objectives are to: Maintain a benchmarking process for food safety management schemes to work towards convergence between food safety standards, as outlines in this Guidance Document. Improve cost efficiency throughout the food supply chain through the common acceptance for GFSI recognized standards by retailers around the world. Provide a unique international stakeholder platform for networking, knowledge exchange and sharing of best food safety practice and information.

GFSI – Audit • Systematic and functionally independent examination to determine whether activities and related results comply with a conforming scheme, whereby all the elements of this scheme should be covered by reviewing the suppliers’ manual and related procedures, together with an evaluation of the production facilities. GFSI - Food safety management scheme • Certification scheme aimed at enhancing food safety.

GFSI - Non-conformity • Deviation of product or process from specified requirements, or the absence of, or failure to implement and maintain, one or more required management system elements, or a situation which would, on the basis of available objective evidence, raise significant doubt as to the conformity of what the supplier is supplying.

GSFI Auditing System Reviews Primary production Processed food

GFSI - Key Element: food safety management systems General Requirements Corrective Action Control of Non-conformity Product Release Purchasing Supplier Performance Traceability Complaint Handling Serious Incident Management Control of Measuring & Monitoring Devices Product Analysis

GFSI - Key Element: food safety management systems General Requirements Food Safety Policy Food Safety Manual Management Responsibility Management Commitment Management Review Resource Management General Documentation Requirements Specifications Procedures Internal Audit

GFSI - Key Elements for GAP, GMP, GDP Stock Management (rotation) Housekeeping, Cleaning & Hygiene Water Quality Management Waste Management Pest Control Veterinary Medicine Pesticide, Herbicide & Fungicide Control Transport Personal Hygiene, Protective Clothing & Medical Screening Training

GFSI Section Key Elements for GAP, GMP, GDP (cont. ) Facility Environment Local Environment Facility Layout and Product Flow Fabrication Equipment Maintenance Staff Facilities Physical & Chemical Product Contamination Risk Segregation & Cross-contamination

GFSI – Global Food Safety Institute Approved auditing schemes: The International Food Standard (IFS), based in Paris, Safe Quality Food (SQF) based in Arlington, USA The British Retail Consortium (BRC) based in London The Dutch Hazard Analysis Critical Control Points food safety system (Dutch HACCP) based in Apeldoorn. Submitted: Food Safety System Certification (FSSC) 22000

The Foundation for Food Safety Certification Key elements: Inte ractive communicatio n, • Food Safety System Certification 22000 • System management • Prerequisite programs • HACCP principles. ISO 22000 – Food Safety Management Systems – Requirements for any organization in the food chain. PAS 220 Publicly Available Specification 220: 2008

Food Safety System Certification 22000 Other ISO Related References ISO 9001 – Requirements for a quality management system that can be used for internal application by organizations. ISO 19011: 2002 Guidelines for quality and/or environmental systems auditing. ISO 9000: 2005 Quality Management Standards – fundamentals & vocabulary.

BRC Global Standard for Food Safety First audit scheme to be approved by GFSI in 2000. Two key components: Senior management commitment and HACCP Each clause of the standard begins with a “statement of intent” to which a company must comply to be certified. Fundamental requirements that relate to systems that are crucial to the establishment and operation of an effective food safety program.

International Food Standard (IFS) Standard developed by: • German and French food trade associations • Other international retailers

International Food Standard (IFS) Five Chapters of subject requirements: Senior Management responsibility Quality management system Resource management Production process Measurements, analysis and improvements

Safety Quality Food (SQF) SQF First launched in 1994 The Food Marketing Institute (FMI) acquired the rights to the SQF program in 2003. • SQF Institute (SQFI) division manages the program. Safe Quality Food 2000 Code HACCP-based quality management system to reduce the incidence of unsafe food. Includes product quality requirements.

SQF Levels of certification Two different standards, or "codes“ • SQF 1000 for primary producers (farms) and • SQF 2000 for manufacturers (processing plants). The SQF 2000 Code is divided into three certification levels: • Level 1 Covers food safety fundamentals; • Level 2 Certified HACCP food safety plans are recognized by GFSI • Level 3 Comprehensive food safety and quality management system actions exceed the GFSI benchmark requirements.

Auditing System Criteria Review Person-in-Charge (PIC ) Duties related to cold food temperature control • Storage • Preparation • Display • Monitoring Food Temperature

Auditing System Criteria Review

Auditing System Criteria Review