HACCP

HACCP

SOPs
PRPs
 PRPs
• Prerequisite Programs :
Practices and conditions needed prior to and
during the implementation of HACCP and which
are essential for food safety as described in the
Codex General Principles of Food Hygiene and
other Codes of Practice.
. Prerequisite programs ensure the HACCP plan
concentrates on the most significant hazards .
• The effectiveness of programs is determined by
carrying out internal and external audits.
 What are the prerequisites for
HACCP?
• GMPs
• GHPs
• SOPs and SSOPs
• Approved suppliers
• Calibration
• Stock rotation
• Good housekeeping
• Crisis management
• Quality Systems Policy
• Food Safety & Quality Systems
• Traceability & Recall
• Pest Control Program
 What are the prerequisites for
HACCP?
• Documentation & Record Control
• Allergen Awareness/Management Program
• Foreign Material & Defect Control
• Process Control
• Line Clearance
• Cleaning / Sanitation
• Preventative Maintenance
• Food Defense/Plant Security
• Corrective Action System/Customer Complaints
• Chemical Control Program
• Internal Audits
• Microbiological Control Program
 Approved suppliers
• Purpose:
Control supply_ ensuring applicable food safety
Agree of material supply according to codex
.. Expectation results:
1-An assigned person responsible for maintaining
program.
2-system input procedures
3-external communication with suppliers
4-complet control food safety
 Calibration
• Purpose:
Ensure validity of measuring tools and correct
verification for food safety system.
.. Expectation results:
1-An assigned person responsible for
maintaining program.
2- GMPs
3-Control HACCP
 Stock rotation
• Purpose:
Control for input and output (FIFO) for all
production material and tools for food safety and
decrease contamination.
.. Expectation results:
1-An assigned person responsible for maintaining
program.
2-control food safety
3-material rotation procedures
 Quality Systems Policy
• Purpose:
This program should define how management will
insure products produced are safe, comply with
regulations, and meet customer expectations.
.. Expectations:
Management commitment to quality and food
safety
Crisis management
Notification of change
Continuous Improvement
 Food Safety & Quality Systems
• Purpose:
The goal of this program is to ensure raw materials and finished products
meet all local and federal food safety regulations as well as specification.
.. Expectations:
• An assigned person/position responsible for maintaining program
• Certificate of Analysis (COA) or Certificate of Conformance (COC)
– Facility should not allow chemicals, raw materials, or label material to be used
in the process without being accompanied by a guarantee that specification is
met
– A procedure addressing materials receipt and missing documentation (e.g.
how to obtain the documentation, what to do with materials prior to receipt
of COA, responsibilities and expectations of suppliers)
• Letters of Guarantee (LOG)
– An assurance letter shall be supplied stating that finished product meets
regulatory compliance for specified packaging material
• Other guarantees (e.g. heavy metals compliance, Proposition.)
 Traceability & Recall
• Purpose:
The goal of this program is to protect the customer from the possible event of
a product safety failure by removing all suspect products from the
distribution channels in the least amount of time, once a product recall or
withdrawal is warranted and initiated.
.. Expectations:
• An assigned person/position responsible for managing the program
• Mock recall should be performed (forwards to the customer and backwards to the raw
materials) at least annually in which lot traceability is maintained
• Mock recall should include the following items:
– Scope/Summary of the recall – e.g. what was the product, lot information, time, %
recovery, was the recall successful and meet expectations
– Inventory/shipment and processing records
– Recall and notification procedures including contact information
– Action plans
– Product disposition and guidelines
– Hold area procedures
– Contact information for customers and regulatory agencies
•
•
 Pest Control Program
• Purpose:
The goal of the pest control program is to exclude pests from the plant (e.g. rodents, insects, and
birds). The program is carried out through a licensed company which meets all Federal,
State, and Local regulatory requirements or by a licensed employee. The pest control
program assists the plant in maintaining a pest-free environment.
.. Expectations:
• An assigned person/position responsible for managing the program
• Pest Control Policy
• Licensed & Insured Pest Control Company (unless handled internally) with
current records available
• Internal/External device monitoring logs with trend charts
• Register of approved chemicals/bait that include:
– Name of chemical and area of application
– MSDS’s and sample labels
• Pesticides should be stored off site
• Internal verification of contractor
• Food Safety/GMP training for the PCO
 Documentation & Record Control
• Purpose:
The document control program ensures current and accurate information is
distributed via documentation throughout the plant. A document control
policy shall be in place and audited.
.. Expectations:
• Document retention times shall be defined
• Documentation shall be adequately secured to reduce the
risk of tampering
• Good record keeping practices shall be followed
• Ensure records are adequate to confirm conformance to
specified standards and to demonstrate the quality system is
effective
 Allergen Awareness/Management
Program
• Purpose:
The allergen control program ensures facility has
evaluated processes and facility to mitigate any
risk of allergen related food safety incidents.
..Expectations:
• An assigned person/position responsible for
managing the program
• Program shall include annual employee training
on allergen awareness as well as on specific areas
based on the type of material being produced
 Allergen Awareness/Management
Program
• Program should consider 3 areas of allergen uses in the plant:
1-Packaging printing/artwork control (prevent potential mislabeling of
foods)
• Verification that print copy matches customer proof copy
• Layout of copy to prevent potential for materials to be mixed after printing/cutting/stacking
• Control of printing plates, cylinders, and blankets to prevent use of obsolete or incorrect media
• Control of materials within the manufacturing process to prevent mixing of materials within a box,
roll, skid, pallet, etc
2-Raw materials/processing aids that contain allergens (e.g. wheat, soy)
• Evaluation should be completed yearly or any time a new material is introduced to
the process to determine any allergens are present in raw materials and processing
aids
• If allergens are present appropriate cleaning/sanitizing steps must be taken along
with appropriate testing/verification
3-Allergen presence in the facility
• Evaluation should be completed to determine if any allergens are present in
vending machines, employee lunches, etc
Foreign Material & Defect Control
• Purpose:
Designed to ensure facility minimizes any foreign or extraneous
material contamination
.. Expectations:
• Glass / Brittle Plastics / Ceramics Control Program –
– Register of all glass, brittle plastics, and ceramics in production areas
– Register should be audited on predetermined basis (should be based
on risk) – e.g. computer monitors, lab equipment, structural glass,
gauges, lights, doors, alarms, fork truck lights, etc.)
– Items should be replaced with shatterproof versions if available
– Clean up / Product Isolation Procedure
• Other process controls should be considered based on feasibility
1-Vision systems
2-Metal detectors
 Process Control
• Purpose:
All employees are part of facilitating a quality assurance program to
ensure 100% compliance to the company and customer standards
.. Expectations:
• An assigned person/position responsible for managing the program
• Testing and quality checks at pre-determined frequencies
• Use of statistical process control to determine capabilities
• Equipment calibration program
• Employee training program
• Quality documentation completed and reviewed by quality or
operations personnel
 Line Clearance
..Purpose:
• To minimize the potential of product mix, all labels, packing
material, documentation, and previous products run shall be
removed from the machine and surrounding area prior to brining
materials for the next job to the work area
..Expectations:
• Program should include but not limited to:
• An assigned person/position responsible for managing the program
• Line clearance shall be documented and a secondary inspection is
recommended
• Line clearance records shall be retained following existing company
policy
 Cleaning / Sanitation
..Purpose:
• This program will vary based upon the products and processes at the
facility. The goal of the program is to maintain a sanitary/clean
environment necessary for the production of food packaging of the
highest quality and safety.
..Expectations:
• Program should include but not limited to:
• An assigned person/position responsible for managing the program
• Detailed cleaning/sanitizing instructions for each piece of equipment or
area. Instructions should include chemicals used and concentrations.
• An approved cleaning/sanitizing chemical list and areas/equipment used
• Cleaning schedule that defines frequency of each piece of equipment /
area
 Preventative Maintenance
..Purpose:
• This program is designed to inspect and prepare equipment to ensure
precise performance.
..Expectations:
• Program should include but not limited to:
• An assigned person/position responsible for managing the program
• Tracking of equipment undergoing maintenance and temporary
repairs
• Preventative maintenance schedule with frequencies and verification
• A tools and parts control/reconciliation program
• Preventive maintenance instructions should include a
cleaning/sanitation step and/or inspection procedures before
machine is put back into production
• All PM’s should be documented
 Food Defense/Plant Security
..Purpose:
• The facility shall have systems in place to ensure the security of the
workplace and that products have not been adulterated or
misbranded
..Expectations:
• Program should include but not limited to:
• An assigned person/position responsible for managing the program
• Security audits shall occur at least yearly or if major changes have
occurred to building and equipment
• Obsolete/unused printed packaging materials shall be disposed of
properly (e.g. defaced, destroyed, shredded, etc.)
 Corrective Action System/Customer
Complaints
..Purpose:
• The goal is to resolve all customer complaints quickly, completely,
and to the satisfaction of the customer and the plant.
..Expectations:
• Program should include but not limited to:
• An assigned person/position responsible for managing the program
• Customer complaint procedure
• Identification of food safety versus quality issue
• Root cause analysis
• Follow-up & corrective action plan
• Response to the customer
• Disposition of product
 Chemical Control Program
..Purpose:
• The goal of this program is to eliminate the possibility of contamination of food contact
surfaces and finished products with non food grade substances. This program also protects
employees and the production area from exposure to hazardous chemicals by managing the
purchase, receiving, storage, mixing, labeling and use of all chemicals in the plant.
..Expectations:
• Program should include but not limited to:
• An assigned person/position responsible for managing the program
• An approved chemical list with intended uses
• Chemical storage areas should be segregated and controlled
• Training
• Hazardous Communication / Emergency Procedures
• MSDS
– Facility should maintain a MSDS program and not allow chemicals to enter facility unless approved
and accompanied by material safety data sheet
– MSDS’s should be available to all employees
•
 Internal Audits
..Purpose:
• The facility shall follow a strict documented self-auditing program
of quality and food safety programs, which involves the
participation of all managers to be audit ready and in compliance.
..Expectations:
• Program should include but not limited to:
• An assigned person/position responsible for managing the program
• A written procedure and audit check sheet
• The audit frequency
• A written report and documented corrective actions
• Key performance indicators for the plant
 Microbiological Control Program
..Purpose:
To ensure the risk of microbiological contamination is evaluated and
controlled. Micro testing requirements will vary based upon products,
processes, government, and industry requirements.
..Expectations:
• Program should include but not limited to:
• An assigned person/position responsible for managing the program
• Documentation from municipality or lab indicating water in facility
is potable
• If facility uses water-based processing aids (e.g. mandrel lubricants),
measures should be taken and documented to ensure micro
contamination is not present. Verification is recommended by an
outside laboratory.
 SOPs
( standard operating procedures)
• SOPs are written protocols for specific activities
or tasks in an operation.
• An example of an SOP might be the written
description of how to measure sanitizer
concentration in wash water.
• The value of a written SOP is to ensure that
critical practices are performed consistently.
• SOPs may cover any number of common
activities, from pre-operation and operation
procedures to prevent contamination.
 SOPs
An SOPs defines as:
• 1. Who is doing the job or task.
(WHO)
• 2. The purpose for doing the job or task.
(WHY)
• 3. Identifies what the job or task is.
(WHAT)
• 4. Identifies steps for completing the job or task.
(HOW)
 SOPs
• EXAMPLE: CATRING (Serving food )
a- Personal Hygiene
• PURPOSE:
To prevent contamination of food by foodservice employees.

• PROCEDURES:
• 1. Follow the District Employee Health Policy.
• 2. Report to work in good health, clean, and dressed in clean attire.
• 3. Change apron when it becomes soiled.
• 4. Wash hands properly, frequently, and at the appropriate times.
• 5. Keep fingernails trimmed, filed, and maintained so that the edges are cleanable and not
• rough.
• 6. Do not wear artificial fingernails or fingernail polish.
• 7. Wear single-use gloves.
• 8. Do not wear any jewelry except for a plain ring such as a wedding band.
• 9. Treat and bandage wounds and sores immediately. When hands are bandaged, single use
gloves must be worn.
 SOPs
• 10. Cover a lesion containing pus with a bandage. If the lesion is on a hand or wrist, cover
with an impermeable cover such as a finger cot or stall and a single use glove.
• 11. Eat, drink, use tobacco, or chew gum only in designated break areas where food or food
contact surfaces may not become contaminated. Only drinks that have covered lids and
straws may be consumed in these designated areas.
• 12. Taste food the correct way:
Place a small amount of food into a separate container.
Step away from exposed food and food contact surfaces.
Use a teaspoon to taste the food.
Remove the used teaspoon and container to the dish room.
Never reuse a spoon that has already been used for tasting.
Wash hands immediately.
• 13. Wear a hair net while in the kitchen.
• 14. Before working on the serving line, employees will check appearance.
Hair should be neatly arranged.
Clothing and apron should be clean.
Make up (if worn) should be fresh.
 SOPs
• MONITORING:
The foodservice manager will inspect employees
when they report to work to be sure that each
foodservice employee is following this SOP.
• CORRECTIVE ACTION:
Retrain any foodservice employee found not
following the procedures in this SOP.
• VERIFICATION AND RECORD KEEPING:
The foodservice manager will record in personnel
records, any personal hygiene issues with an employee.
 SOPs
b-Receiving Deliveries
• PURPOSE:
To ensure that all food is received fresh and safe when it enters the foodservice
operation and to transfer food to proper storage as quickly as possible.

• PROCEDURES:
• 1. If possible, schedule deliveries to arrive at designated times during operational hours.
• 2. Post the delivery schedule, including the names of vendors, days and times of deliveries,
and drivers’ names.
• 3. Organize freezer and refrigeration space, loading docks, and store rooms before deliveries.
• 4. Gather product specification lists and purchase orders, temperature logs, calibrated
thermometers, pens, flashlights, and clean loading carts before deliveries.
• 5. Keep receiving area clean and well lighted.
• 6. Do not touch ready To eat foods with bare hands.
• 7. Compare delivery invoice against products ordered and products delivered.
• 8. Transfer foods to their appropriate locations as quickly as possible
 SOPs
• MONITORING:
• 1. Be sure refrigerated foods are delivered in a refrigerated truck.
• 2. Confirm vendor name, day and time of delivery, as well as driver’s identification before accepting
delivery.
If driver’s name is different from what is indicated on the delivery schedule, contact the vendor
immediately.
• 3. Check frozen foods to ensure that they are all frozen solid and show no signs of thawing and
refreezing, such as the presence of large ice crystals or liquids on the bottom of cartons.
• 4. Check the temperature of refrigerated foods
For fresh meat, fish, and poultry products, insert a clean and sanitized thermometer into the
center of the product to ensure a temperature of 41 ºF or below.
The temperature of milk should be 45 ºF or below.
For packaged products, insert a food thermometer between two packages being careful not
to puncture the wrapper.
If the temperature exceeds 41 ºF, it may be necessary to take the internal temperature before
accepting the product.
• 5. Check dates of milk, eggs, and other perishable goods to ensure safety and quality.
• 6. Check the integrity of food packaging.
• 7. Check the cleanliness of crates and other shipping containers before accepting products.
• Reject foods that are shipped in dirty crates.
 SOPs
• CORRECTIVE ACTION:
Reject the following:
Frozen foods with signs of previous thawing.
Cans that have signs of deterioration, such as swollen sides
or ends, flawed seals or seams, dents, or rust.
Punctured packages.
Food with out dated expiration dates.
Foods that are out of safe temperature zone or deemed
unacceptable by the established rejection policy.
• VERIFICATION AND RECORD KEEPING:
Record the temperature and the corrective action on the
delivery invoice.
 SSOPs
Sanitation Standard Operating Procedures
• SSOPs are written protocols describing how
facilities and equipment are washed and
sanitized. An SSOP includes a listing of the
cleaning and sanitation chemicals to be used, the
appropriate concentration levels, the methods to
be followed, and how sanitation effectiveness is
measured.
• Sanitation is not limited to cleaning equipment, it
also includes personnel practices, facilities,
equipment design and operation, pest control,
and warehousing and waste disbosal.
 SSOPs
• How do I write and use an SSOP?
• They address the pre-operational and operational
procedures to prevent product contamination, and are
a central building block of a rigorous food safety
program.
• Facility sanitation tasks are typically described as
SSOPs. Each SSOP describes a specific task in the form
of a detailed recipe for performing that task. The
“recipe” should be detailed enough, and clear enough,
so that a sanitation shift worker can follow the
procedure and achieve a sanitary surface.
 SSOPs Example
SANITATION OF CONVEYOR BELTS
• GOAL:
Prevent buildup of organic matter and microorganisms on
conveyors so that they do not become a source of contamination.
• IMPORTANCE:
Dirty conveyor belts can contaminate products that contact them.
• FREQUENCY:
Monthly
• TOOLS AND EQUIPMENT:
Potable water, hose, stiff plastic long-handled brush, soap,
pressurized soap applicator, peroxide sanitizer, backpack sprayer,
check sheet.
 SSOPs Example
• Procedures:
• A. Remove belts from conveyors.
B. Thoroughly rinse equipment, from top to bottom, with a pressure washer until all loose carrot
sludge, bits and pieces have been removed.
• C. Mix soap as follows: ______________
• D. Apply soap with the pressurized soap sprayer.
• E. Scrub vigorously to remove small pieces of carrot and to remove invisible films.
• F. Rinse thoroughly a second time to remove all of the soap. The soap must be rinsed in order for
the sanitizing solution (peroxide) to be effective.
• G. Reinstall the belts.
• H. Mix peroxide solution as follows: _______________
• I. All of the belts must be sprayed with the peroxide solution. The sanitizing solution is applied with
a backpack sprayer.
• J. The Sanitation Crew Chief then inspects all sanitized surfaces.
• K. The Sanitation Crew Chief writes the time and date, and signs the sanitation log for each
individual belt. If any belt does not pass inspection, the Crew Chief notes that in the log and the
crew must rewash and re-sanitize that belt until it passes inspection.
• L. Replace belts
 SSOPs
• After the task has been completed, the cleaned and sanitized surface can
be swabbed and the swab sent to an appropriate lab for testing to verify
the SSOP’s effectiveness. Swab tests, the most common method of
conducting environmental monitoring, typically target indicator organisms
such as Listeria species or environmental pathogens such as Listeria
monocytogenes or Salmonella.
• If the cleaning and sanitizing methods described in the SSOP are effective, the
swab test result should show few or no viable bacteria on the swabbed
surface. If, however, there are significant numbers of viable bacteria, then the
SSOP is ineffective and sanitation methods need to be reevaluated and
improved. In this way, all of the SSOPs can be improved and validated .
 SSOPs
• Having validated the SSOP, the sanitation team must follow its
instructions, with confidence that the result will be sanitary surfaces. Such
an approach of developing validated SSOPs for all cleaning and sanitation
tasks results in a rigorous sanitation program that has been proven
effective. The operator will thus have a high degree of confidence that the
surfaces that have been cleaned and sanitized are, indeed, sanitary and
reliably free of contaminants.
• Another benefit of this approach is that it becomes unnecessary to
constantly swab surfaces to verify that they are sanitary. The validated
SSOP ensures that they are, as long as the sanitation crew faithfully
follows the SSOP’s validated procedures. Revalidation of the SSOP is
necessary if products, processes or procedures change.