Implementation of food quality systems e g HACCP

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Implementation of food quality systems (e. g. HACCP, traceability) in a foodstuff-producing enterprise How

Implementation of food quality systems (e. g. HACCP, traceability) in a foodstuff-producing enterprise How did Confiserie Roodthooft organize HACCP, traceability and other EU requirements in the field of food hygiene and food quality in its facilities? With the support of the European Commission

 • Background • Food Safety & Hygiene • Energy Savings (additional topic) •

• Background • Food Safety & Hygiene • Energy Savings (additional topic) • Questions With the support of the European Commission

Background • Patrick Stoops • Confiserie Roodthooft Managing Director • Producing Confectionery (sweets &

Background • Patrick Stoops • Confiserie Roodthooft Managing Director • Producing Confectionery (sweets & chocolates) With the support of the European Commission

Background • A traditional family company in Antwerp – Belgium • Founded in 1925

Background • A traditional family company in Antwerp – Belgium • Founded in 1925 by Louis Roodthooft and Joanna Stoops With the support of the European Commission

Background • • brands “Bonbons Prima” and “Roodthooft” Manufacturer of quality sweets and toffees

Background • • brands “Bonbons Prima” and “Roodthooft” Manufacturer of quality sweets and toffees Winner of prizes for quality “Brand leader” With the support of the European Commission

Background • Products: – – MOKATINE ® PICKERS ® TOFFEE Our Original Belgian Toffees

Background • Products: – – MOKATINE ® PICKERS ® TOFFEE Our Original Belgian Toffees ® LOLLYPOPS – CARAMELS / TOFFEES (fruit & traditional flavours e. g. cream, milk, chocolate) – CHOCOLATE COVERED PRODUCTS – HARD-BOILED CANDIES With the support of the European Commission

Background • Main raw materials: – Sugar – Glucose – Milk (condensed) – Vegetable

Background • Main raw materials: – Sugar – Glucose – Milk (condensed) – Vegetable oil – Flavourings (e. g. coffee) With the support of the European Commission

Background • The production process With the support of the European Commission

Background • The production process With the support of the European Commission

Background • The packaging proces With the support of the European Commission

Background • The packaging proces With the support of the European Commission

Food Safety & Hygiene • International Requirements – Codex Alimentarius • EU Food Safety

Food Safety & Hygiene • International Requirements – Codex Alimentarius • EU Food Safety & Hygiene – Online: http: //europa. eu. int/eur-lex • => GMP + HACCP With the support of the European Commission

Food Safety & Hygiene • • • Medical screening of production staff Licence for

Food Safety & Hygiene • • • Medical screening of production staff Licence for foodstuffs Machine directive Food hygiene (EU 852/2004, 01/01/06) Microbiological criteria Water quality, etc. With the support of the European Commission

Food Safety & Hygiene • Belgian System = autocontrole – Ministry and Industry implement

Food Safety & Hygiene • Belgian System = autocontrole – Ministry and Industry implement together – Autocontrole (self-evaluation) guide = basis • Written by the industry – University + industry experts • Certified by the Ministry for food safety • => certified handbook for industry, ministry and all certifying companies With the support of the European Commission

Food Safety & Hygiene • GMP • Good Manufacturing Practices • Best Available Practices

Food Safety & Hygiene • GMP • Good Manufacturing Practices • Best Available Practices • Financial resourses • non productive investments = cost increasing • Hidden cost savings • Autocontrole (self-evaluation) guide • Staff – task force – external advisors = SOLID BASE With the support of the European Commission

Food Safety & Hygiene • Production Framework – Buildings – Machinery • Production Procedures

Food Safety & Hygiene • Production Framework – Buildings – Machinery • Production Procedures – HACCP – Tracking & Tracing With the support of the European Commission

Production Framework • Buildings – EU and International Requirements – How to implement these

Production Framework • Buildings – EU and International Requirements – How to implement these • New buildings V. old buildings – – – Floors Walls & ceilings Access & product flow Doors & windows Pest control With the support of the European Commission

Production Framework floor renovation With the support of the European Commission

Production Framework floor renovation With the support of the European Commission

Production Framework • tips: – Hidden cavities behind false walls : BAD – Prefer

Production Framework • tips: – Hidden cavities behind false walls : BAD – Prefer drainage points, not floor-level gutters – Only use quality materials With the support of the European Commission

Production Framework • Machinery – Requirements ( hygiene & safety) – Plant Design •

Production Framework • Machinery – Requirements ( hygiene & safety) – Plant Design • Batch processing or continuous processing • Machine safety for product and operator • Cleaning With the support of the European Commission

Production Framework old v. With the support of the European Commission new

Production Framework old v. With the support of the European Commission new

Production Procedures • HACCP – Hazard Analysis and Critical Control Points – Pronounced as

Production Procedures • HACCP – Hazard Analysis and Critical Control Points – Pronounced as [HASAP] – Expert advice for: • Administrative procedures • Staff training : – HACCP Taskforce members specific training – All staff general hygiene and procedures training • On hand advice in case of problems With the support of the European Commission

Production Procedures – HACCP for taskforce: • Content: – Production process flowsheets » Production

Production Procedures – HACCP for taskforce: • Content: – Production process flowsheets » Production steps » Geographical flows – Define ALL possible hazards – Analyse and classify into CRITICAL and NON-CRITICAL Hazards With the support of the European Commission

Production Procedures • Actions: – Eliminate the hazards – Verify the success of elimination

Production Procedures • Actions: – Eliminate the hazards – Verify the success of elimination » Automatic and 100% sure => no CCP » Not 100% sure => CCP definition • Documentation and handbook – Worksheets for production – Worksheets for cleaning – Handbooks With the support of the European Commission

Production Procedures • Supplier information: – Documentation on goods – Certificates » Direct Contact

Production Procedures • Supplier information: – Documentation on goods – Certificates » Direct Contact Food use » Non migration » Inks used (not lead-based) – Covered by insurance – Prepared for additional info in case of problems With the support of the European Commission

Production Procedures – Staff training » Commercially available training films » Company-oriented extra training

Production Procedures – Staff training » Commercially available training films » Company-oriented extra training – Verify the implementation – Organise tests » Finished products » Incoming products With the support of the European Commission

Production Procedures • Tracking and Tracing: – Analyse your production stages – What is

Production Procedures • Tracking and Tracing: – Analyse your production stages – What is used where ? – Bulk (silo or tanks) or batch storage – Bulk or batch production – Limited quantity of products or huge numbers => lot size ? With the support of the European Commission

Production Procedures • Raw materials: – Sugar – Glucose – Chocolate With the support

Production Procedures • Raw materials: – Sugar – Glucose – Chocolate With the support of the European Commission

Production Procedures • Raw materials: – Sugar bags – Glucose bulk – Chocolate blocks

Production Procedures • Raw materials: – Sugar bags – Glucose bulk – Chocolate blocks With the support of the European Commission

Production Procedures • Raw materials: – Sugar bags lot OK – Glucose bulk lot

Production Procedures • Raw materials: – Sugar bags lot OK – Glucose bulk lot ? – Chocolate blocks lot OK With the support of the European Commission

Production Procedures • Raw materials: – Sugar lot OK easy tracing – Glucose lot

Production Procedures • Raw materials: – Sugar lot OK easy tracing – Glucose lot ? lot-1/lot+1 – Chocolate lot ? lot-1/lot+1 With the support of the European Commission

Production Procedures • Database of Raw Materials – Per raw material • • Quantity

Production Procedures • Database of Raw Materials – Per raw material • • Quantity delivered Supplier LOT number(s) Per LOT : production days – Log, search and retrieve With the support of the European Commission

Production Procedures • Our products – Process = batch continuous – Thousands of products

Production Procedures • Our products – Process = batch continuous – Thousands of products per minute – Look / is all the same – How do we define the lot of each one ? • cost acceptable system – one day = one lot With the support of the European Commission

Production Procedures • Our products: – Products stored in crates after wrapping • Each

Production Procedures • Our products: – Products stored in crates after wrapping • Each crate is labelled • Product bunkers are labelled – Lot number on bags and boxes – One day = acceptable RECALL quantity – acceptable RECALL cost With the support of the European Commission

Production Procedures • Warehousing and Logistics – Pallets by SSCC code • Structure of

Production Procedures • Warehousing and Logistics – Pallets by SSCC code • Structure of the code = UA 128 – – – 1 st digit = type of pallet (full, not full, client ready) Next digits = company number Pack date Sequential number pallet Control digit • Database with SSCC codes With the support of the European Commission

Production Procedures • Database: – SSCC code – Product name + type – Best

Production Procedures • Database: – SSCC code – Product name + type – Best before date = visible LOT number – Initial quantity + remaining quantity – In/out movements – Quantities, destination, dates, truck nr. With the support of the European Commission

Production Procedures • Requirements: – Log all movements per lot – Search + compile

Production Procedures • Requirements: – Log all movements per lot – Search + compile lists – Time frame < 2 hours – Link to raw materials used per lot – Link to production staff and machines – => traceability With the support of the European Commission

Production Procedures • Safety requirements: – Emergency contact phone/fax/email – 24 / 7 –

Production Procedures • Safety requirements: – Emergency contact phone/fax/email – 24 / 7 – Clients + suppliers With the support of the European Commission

Production Procedures • Recall procedures – Insurance policy ? – Client – supplier information

Production Procedures • Recall procedures – Insurance policy ? – Client – supplier information – Press release – Company – Ministry information With the support of the European Commission

Energy Savings • CONCERN for the environment – Global warming – Air pollution –

Energy Savings • CONCERN for the environment – Global warming – Air pollution – Water pollution – Shortage of drinking water • CONCERN for finances With the support of the European Commission

Energy Savings • Electricity: – Frequency inverters / soft starters – Motion detection for

Energy Savings • Electricity: – Frequency inverters / soft starters – Motion detection for lights With the support of the European Commission

Energy Savings • Heating: – Double glazing + mirrored glass – Airtight doors –

Energy Savings • Heating: – Double glazing + mirrored glass – Airtight doors – Selective heating With the support of the European Commission

Energy Savings • Steam boiler: – Well insulated pipes – Optimal re-use of steam

Energy Savings • Steam boiler: – Well insulated pipes – Optimal re-use of steam condensate – economiser – Exhaust valve ! With the support of the European Commission

Energy Savings • Green energy – Photovoltaic cells ? – Wind turbine ? –

Energy Savings • Green energy – Photovoltaic cells ? – Wind turbine ? – Heat pump – Absorption cooling (Ammonia-water) With the support of the European Commission

QUESTION TIME ? With the support of the European Commission

QUESTION TIME ? With the support of the European Commission