Introduction to HACCPDeveloped by

AgendaFood safetyResponsibilitiesHACCPPrerequisite programsHACCP plans Control measures and CCPs

Food SafetyPrevention of hazards in foodsPhysicalBiologicalChemicalAllergens

Responsibility for food safetyProducer/growerManufacturerDistributorTransporterRetailerConsumer

Industry ResponsesConsumer education

HACCP and HACCP based Food safety programs for all sectors

HACCPazard

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WHAT hazards can enter the product?

Where do these hazards occur?

How can we control or eliminate these hazards?

HACCP - Answers 3 questions

HACCPScience based Step wise process:Identifies hazardsInstalls preventative measures to eliminate or reduce hazards in foods Proactive rather than reactiveRisk based

HACCPDoes not rely on end product testinghazards not be evenly distributed and can be missed in samplingneed to test large quantitiesproduct would need to be destroyed or reworked

HACCPStarts from the beginning of the processReceiving of ingredients, packaging through process steps to final product and shipping

Pillsburycome as close to 100% assurance as possible that food products would not be contaminated with pathogens.needed control over raw materials, environment and people as early in the system as possible.

ComponentsPre-requiste programHazard analysis

PrerequisitesFoundation to a HACCP program

Includes Good Manufacturing Practices

Addresses food safety at all stages from receiving to shipping Including indirect hazards

Prerequisite programPremisesTransportation and StorageEquipmentPersonnel/TrainingSanitation and Pest ControlRecallAllergen ControlSupplier Quality Assurance

Premises Outside property and building Design, construction & maintenance Lighting Ventilation Waste disposal Inedible areas Employee & sanitary facilities Water/Steam/Ice

Transportation and StorageFood CarriersTemperature ControlsReceiving and Storage Incoming ingredients and packagingNon-Food Chemicals Finished Product Storage

EquipmentDesign and installation

Maintenance and Calibration

PersonnelTrained for their job

Understand food safety

Sanitation and Pest Control SanitationEquipment and UtensilsFloorsLocker roomsLunch roomsWashroomsPest control

Recall Product identification

Locating product

Returning product

Allergen control Identification of Allergens Control of allergensSpecial handlingSegregateSpecial sanitation proceduresReworkProper labelling

Supplier Quality Assurance Vendor approval process

Product specifications

Inspect incoming materials

Now on to the HACCP plan .

Sequence of 12 StepsAssemble HACCP teamDescribe productIdentity intended useConstruct process flow and plant schematicOn site verification of flow and schematicList hazards associated with each process step (principle #1)

Sequence of 12 steps7. Apply HACCP decision tree to determine CCPs (Principle #2)Establish critical limits (Principle #3)Establish monitoring procedures (Principle #4)Establish deviation procedures (Principle #5)Establish verification procedures (Principle #6)12. Establish record keeping/documentation for principles 1 - 6 (Principle #7)

HACCP teamPeople chosen that have expertise in different areas:ProductionShippingQuality AssuranceSanitationMaintenanceSales

Product DescriptionProduct Name(s)Important Product Characteristics How it is to be usedPackagingShelf LifeWhere it will be soldLabelling InstructionsSpecial Distribution ControlSpecific Ingredients

Define the processing steps

Construct Plant Schematic

Your Establishments Plant Schematic Here

Determine hazardsLook at each input- ingredientsDetermine possible hazardsHow are they controlled?

CCPsCritical control pointsPlace where you can prevent, remove or reduce a hazard if there is not step in the process that can eliminate or reduce the hazards- use labelling, cooking instructions to inform how control can be achieved

Our CCPSMetal detectorMetal is a hazard in our facilityNot fully controlled by any prerequisite programMetal detectors specifically designed identify product containing metalThat product can be removedNo other step will remove the metal

CCPsWhat is your role?

MonitorLook, smell, measureRecordCorrective actions VerifyMonitor people doing activityTake corrective actions when necessaryComplete records properly

Practical application

On the job.....Watch for hazards and remove any that you findIf you are involved in CCP monitoring:Perform your checks as required:according to procedureon time

Today we are going to discuss an internationally recognized food safety system, that we use to help us ensure that the food products we make are safe to eat. Has anyone heard of HACCP? (Let participants answer, finish by thanking them for their answers).**Today, we will discuss the following (read bullet points). It should take about one hour and we will be doing some exercises, to help you learn and so I can get feedback on what you understand*Everyone deserves safe food. In previous sessions we have talked about the different types of hazards that can be found in food products. Can anyone give me an example of a physical hazards? (take answers , write on the flipchart). DO we have them in our facility ? How do we control them? , (expand on what they offer) Examples of biological hazards?Examples of chemical hazards? Allergens?

As you can see, we have specific responsibilities for the foods we manufacture. But we rely on our suppliers producers and growers to give us safe product, and then we count on the people who distribute and transport the product, the stores and their personnel that sell our products and finally the consumer to handle, cook and serve our product to keep it safe.Can anyone give me an example of something a consumer needs to do to keep our products safe?(Here participants may say keeping milk refrigerated, not thawing meat on the counter, buying groceries at the end of a shopping trip, so the food doesnt sit in a hot car etc.)*The food industry provided information to help educate consumers. Such as point of sale information, information on labels, websites with recipes and storage tips. They have also adopted food safety programs that incorporate the principles of HACCP*So what is HACCP? HACCP stands for Hazard Analyses Critical Control point and simply put answers three questions: read bullets.

*It is a science based program that works through a step wise process to identify hazards, put in preventative measures to eliminate or reduce particular hazards in their food products. It is proactive not reactive and is based on risk.*It does not rely on product testing as most Quality control programs have done in the past. Final product testing does not identify or remove all hazards as the hazards may not be evenly distributed and can be missed in sampling. A large number of products would need to be tested in order to get statistically accurate results and most testing of food is destructive so you would have very large waste numbers.*HACCP looks at the entire process from the beginning; the receiving of ingredients, packaging through all process steps to final product and shipping. You document the potential hazards and look at control measures. We have discussed some of our control measures at the beginning of todayss session.

*Developed by Dr. Henry Bauman at Pillsbury in 1960s as part of the space program. As you know it is hard to get medical attention to astronauts in space, so NASA asked Pillsbury to develop a program that could guarantee that the food the astronauts ate would be safe. So HACCP was based on the concept that Pillsbury wanted to come as close to 100% assurance as possible that food products would not be contaminated with pathogens. To do that, they determined that they needed to build safety in and needed control over raw materials, environment and people as early in the system as possible.

*In order to build safety in, there are two parts to a HACCP program: The prerequisite program and the actual HACCP plan. We will talk about each of these tow programs in detail. We have a HACCP team comprised of (add names here) that have spent time developing our program, so I wont go into the details of how the programs are developed, but will give you highlights only.*The prerequisite program is the foundation to a HACCP program. Formerly these were know as Good Manufacturing Practices, which addresss food safety at all stages from receiving to shipping, including the possibility of indirect hazards.

*Our program includes the following elements (Customize here)PremisesTransportation and StorageEquipmentPersonnel/TrainingSanitation and Pest ControlRecallAllergen ControlSupplier Quality Assurance

**Premises looks at all the various aspects of the physical structure of our facility.- Outside property and building, our neighboring companies dont handle toxic compounds or other things that may impact our products, Design, construction & maintenance- the walls are sound, pests can get in through unprotected doors and windows Lighting there is enough light for people to do their jobs, and that the lights themselves do not present a hazard Ventilation there is sufficient air movement and odours, steam etc are removed Waste disposal- we control our garbage Inedible areas- garbage is separated from good food Employee & sanitary facilities we have enough washrooms and they are equipped with hot water, soap, sanitizer and towels Water/Steam/Ice water is potable.

*Transportation and storage looks at how materials is stored in the facility and how products are transported to customers. What are some of the activities that you do in this area? They should come up with some of the following:

Need to do visual inspections Clean packaging if necessaryIf packaging torn or broken, inspect to see if anything is damaged, If everything is okay, then fix add name and date, If not, inform supervisor

Store foods at the proper temperatures. Discussed bacterial growth in hazard module*It is important that equipment is suitable for its intended use and is working properly. How do you make sure of that?

all surfaces that touch the food (food contact surfaces) are non porous, etcHave a good preventative maintenance programCalibrate thermometers, scales, chemical dispensing units

People like you and me are on of the most critical pieces in this program. We have discussed before how what we do at work impacts food safety. It is important that all employees are trained to do their job and understand the implications of their actions of food safety.**We have talked in other sessions about why cleaning and sanitation is important. All parts of the facility need to be cleaned on a regular basis. Pest control is also important as pests such as rodents, flies, birds can bring in hazards into our facility. we have good programs in place to keeps those pests out of our facility. But you need to do your part as well, by keeping doors closed, picking up garbage and cleaning as you go.*A recall is the process of identifying, locating and bringing back any food that contains hazards. How can we identify the particular date when a product was made? Participants should be able to say something about a lot code or production code or best before date. Fill in with your company practices.

So if we get a complaint or know there is something is wrong with a product, we can identify when it was made and then check our records to see what ingredient and their lot codes if necessary were used, what maintenance was done on that day etc. We also have procedures to figure out what other products were affected and what customers received those products.As we discussed in an earlier session, allergens are a special class of chemical hazards. What allergens do we have in our facility?

Go through the list- peanuts, tree nuts, fish and seafood, wheat, eggs, dairy products, soy, sulfites, sesame seeds How do we control them?Special handlingSegregateSpecial sanitation proceduresReworkProper labelling

*Suppliers are also an important part of the process as we rely on them to supply us with safe ingredients and packaging. We have a vendor (or supplier) apporval process where we make sure that they can give us the products that we need to meet our specification. We inspect incoming materials to make sure that they are what we ordered, they are not damaged and that they contain lot codes so we can trace them back if necessary.*The programs that we have just discussed are the foundation to our HACCP program. We have tried to eliminate as many hazards as we can. Now we can turn our attention to the HACCP plan itself.**There is a logical sequence of 12 steps that we used to develop our HACCP plan Read Slide*Read SlideIt is important to have people with different backgrounds on our HACCP team, as they have differing expertise. Our HACCP team includes the following people: (name them by job title, perhaps some of the participants are on the team, If so, ask them to tell the group a little about the team and what they have contibuted)*Briefly, we have examined all our products, assigned them to a group with similar characteristics, Some of the things that we looked at include:Product Name(s)Important Product Characteristics How it is to be usedPackagingShelf LifeWhere it will be soldLabelling InstructionsSpecial Distribution Control the specific ingredients used

*We then defined each of the processing steps from receiving, through storage and handling, preparation, packaging and labeling, storage of finished products and distribution to customers. (Add your own processing steps)*We looked at the plant layout, and how people, ingredients, finished product move through the plant and checked to where potential cross contamination counld occur.*We then listed all the hazards (biological, chemical, allergens and physical) that could possibly enter our product through the ingredients and the process steps and determined if they were controlled and how) and what was not controlled.

*Using a step wise process, we then determined if we had an CCPs. CCPs are critical control points places where we can prevent, remove or reduce a hazards, that is not already controlled by a previous step.*List your companys CCPs here and discuss why they are CCPs, we have used the example of a metal detector We have one CCP in our facility. Does anyone know what it is? The metal detector is a CCP because metal as a hazard cannot be completely controlled by our prerequisite programs and processing steps. There is a possibility that metal can enter our products because we have metal in our facility ; in slicers blades, in screws etc that maintenance uses. The metal detector is specifically designed to identify product containing metal, so it can virtually eliminate metal in all our products*Customize here to add specifics on what the participants roles are in monitoring CCPs There are specific actions that need to be taken on a prescribed timeframe at all CPPs. It is important to measure, look or smell, following the procedures and record your results. The records are how the company can prove that the correct actions were taken . There are CCP logs that need to filled out, (provide examples, show them how they fill them out properly).

If the test that you are doing does not pass, then what do you do? (explain clearly the corrective actions that need to be taken)

All CPP records are verified by ________________. Verification comprises two steps (expand if necessary):Verifying that the person doing the activity is doing it correctly and filling out the records properly and that corrective actions are taken when necessary.**

You will now have 5-10 minutes to complete this short evaluation. Please indicate the type of hazard and one method of eliminating or controlling it. We will then review it as a group and you will mark your own.

In the review, ask each person to give one example and go around the group until all are mentioned.*Summarize the learning concepts and ask for questions. Remember to thank them for their time. Tell them that these activities will be monitored.