G OOD

MANUFACTURING
P R ACTICES

GOOD MANUFACTURING
PRACTICES
Training about our Food Safety Plan
HACCP ACRONYM
G OOD
MANUFACTURING
P R ACTICES

H azzard
A nalysis
C ritical
C ontrol
P oint

Good Management Practices Dec-07 2

HISTORY OF THE HACCP G OOD
MANUFACTURING

SYSTEM P R ACTICES

➢ HACCP was developed in the 1960’s when NASA

asked Pillsbury to design and manufacture the first
food for space flights

➢ 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?
G OOD
MANUFACTURING
P R ACTICES

➢ 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.

➢ With HACCP the food processor systematically:

➢ Identifies potential food safety hazards (Hazard
Analysis).
➢ 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 G OOD

HACCP PLAN
MANUFACTURING
P R ACTICES

➢ Good Manufacturing Practices (GMPs)

➢ Standard Operating Procedures (SOPs)

Good Management Practices Dec-07 5

SOP’s ALLOW YOU TO:
G OOD
MANUFACTURING
P R ACTICES

1. SAY what you do

2. DO what you say

3. PROVE it

Good Management Practices Dec-07 6

WHAT ARE CCPs G OOD
MANUFACTURING

(Critical Control Points)?

P R ACTICES

➢ 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 G OOD
MANUFACTURING

THE SEVEN PRINCIPLES P R ACTICES

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
G OOD
MANUFACTURING
P R ACTICES

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 G OOD
MANUFACTURING

PRACTICES (GMPs) P R ACTICES

➢ 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:
G OOD
MANUFACTURING
P R ACTICES

➢ Preventative measures to ensure food

safety

➢ Based on practical experience over a long

period of time

➢ The foundation on which to build a HACCP

program

Good Management Practices Dec-07 11

STANDARD OPERATING G OOD
MANUFACTURING

PROCEDURES (SOP’s) P R ACTICES

➢ The purpose and frequency of doing a task

➢ Who will do the task

➢ A description of the procedure to be performed

➢ What paperwork is to be completed (documentation)

➢ The method by which you show that task is
satisfactorily completed
➢ And the corrective actions to be taken of the task is
performed incorrectly

Good Management Practices Dec-07 12

CORRECTIVE ACTION G OOD
MANUFACTURING

REQUEST P R ACTICES

➢ A CAR must be ➢ State deviation

completed for each
deviation from the SOP
➢ CAR Form
➢ CAR Instructions
➢ Use objective Evidence
➢ Develop an action plan
to prevent deviation
reoccurrence
➢ Set a deadline

➢ Verify that the action

plan has been
effective

Good Management Practices Dec-07 13

PREREQUISITE PROGRAM: G OOD

PREMISES
MANUFACTURING
P R ACTICES

➢ Building Exterior

➢ Building Interior: Design, Construction,

Lighting, Ventilation, Waste Disposal, Inedible
Areas

➢ Sanitation Facilities: Employee Facilities,

Equipment Cleaning & Sanitizing Facilities

➢ Water/Ice Quality and Supply

Good Management Practices Dec-07 14
PREREQUISITE PROGRAM: G OOD

PREMISES
MANUFACTURING
P R ACTICES

➢ Premises SOP

➢ Monitoring Procedure: part of internal

audit procedures

Good Management Practices Dec-07 15

PREREQUISITE PROGRAM:
TRANSPORTATION, RECEIVING &
G OOD
MANUFACTURING
P R ACTICES

STORAGE

➢ Receiving: Food Carriers, Temperature Control,

Approved Suppliers

➢ Storage: Ingredient, Allergen, Finished Product

and Chemical Storage

➢ Transportation: Food Carriers, Temperature

Control

Good Management Practices Dec-07 16

PREREQUISITE PROGRAM: G OOD
MANUFACTURING

TRANSPORTATION, RECEIVING & STORAGE

P R ACTICES

➢ Transportation Receiving and Storage SOP

➢ Monitoring Procedures: check each

shipment,

➢ CAR: example

➢ Allergen Program

➢ Approved Suppliers Program

Good Management Practices Dec-07 17

PREREQUISITE PROGRAM: G OOD

EQUIPMENT
MANUFACTURING
P R ACTICES

➢ Equipment Design and Installation

➢ Equipment Maintenance and Calibration

➢ Equipment SOP

➢ Temperature Monitoring Log

➢ Thermometer Calibration

Good Management Practices Dec-07 18

PREREQUISITE PROGRAM: G OOD

PERSONNEL
MANUFACTURING
P R ACTICES

➢ Training: Hygiene and Technical

➢ Hygiene and Health Requirements
➢ Personnel SOP
➢ Employee Sanitation SOP
➢ Visitor Log Book

Good Management Practices Dec-07 19

PREREQUISITE PROGRAMS: G OOD

Sanitation & Pest Control

MANUFACTURING
P R ACTICES

➢ SANITATION
➢ PEST CONTROL
➢ SOP
➢ PREOPS CHECKLIST
➢ TRUCK CLEANING LOG

Good Management Practices Dec-07 20

PREREQUISITE PROGRAM: G OOD

RECALL
MANUFACTURING
P R ACTICES

➢ The Recall System

➢ Complaints Log
➢ Complaints Log SOP
➢ Recall Template
➢ Recall Notice
➢ Allergen Alert Notice

Good Management Practices Dec-07 21

CRITICAL LIMITS
G OOD
MANUFACTURING
P R ACTICES

➢ Is a value which separates acceptability

from unacceptability

➢ Critical Limits must meet or exceed

government regulations

➢ One or more critical limit must be met to

ensure a CCP is controlling the hazard

Good Management Practices Dec-07 22

CRITICAL LIMITS
G OOD
MANUFACTURING
P R ACTICES

➢ Temperature / Time
➢ pH
➢ Aw (available water)
➢ Preservatives
➢ Available chlorine
➢ Sensory observations

Good Management Practices Dec-07 23

SOURCES OF CRITICAL LIMITS
G OOD
MANUFACTURING
P R ACTICES

➢ Regulatory Standards

➢ Company Standards

➢ Literature Surveys

➢ Experimental Studies

➢ Expert Advice

Good Management Practices Dec-07 24

CRITICAL LIMITS
G OOD
MANUFACTURING
P R ACTICES

➢ Individual Product Profiles

➢ Process Control Sheet

Good Management Practices Dec-07 25

PRODUCTION RECORDS
G OOD
MANUFACTURING
P R ACTICES

➢ Using CIMS to record ingredients,

batch processing and finished
product information

Good Management Practices Dec-07 26

IMPORTANCE OF VERIFICATION
G OOD
MANUFACTURING
P R ACTICES

➢ Ensures that all major processing steps

have been identified

➢ Validates the assumptions made regarding

the movement of employees and product

➢ Works towards continual improvement of

the GMP system

Good Management Practices Dec-07 27

IMPORTANCE OF VERIFICATION
G OOD
MANUFACTURING
P R ACTICES

➢ Internal Audit

➢ Internal Audit Template

➢ Label Review

Good Management Practices Dec-07 28