Hygienic and Sanitary

Practices for Food

General Manufacturing
– Advance Level
FSMS Planning
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FSMS Program

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Defining the process steps

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Process Information :

Flow Diagrams: Process flow

diagram

Indicating all ingredients, preparation steps, Serving,

Re usage, facilities for cleaning & Disinfection

Depicting storage & preparation,serving areas, personal

facilities, rodent & pest control devices

* Control and periodic verification(at least annual) of the

process information.
Process Flow Diagram

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 Develop Flow Diagrams

• Use Standard Symbols -

Document
Process
Activity

Multi-document

Decision
Connector

Storage
Terminator

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Typical Process Flow Diagram
Biscuit Manufacturing

Receiving of Raw Material

Quality Inspection

Storing

Issue to Production

Preparation of Sugar syrup

Sifting of Maida – 30 Mesh

Addition of Other Ingredients

Mixing (Creaming)

Dough Formation

Moulding, Cutting & Shaping

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Case Study 2

In your groups, make a flow diagram for the processes allocated

by the Tutor. Use flipcharts for presentation.

Preparation time: 20 mins

Presentation Time per group: 5 mins

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Developing an FSMS Plan

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Hazard

A biological, chemical or physical agent in,

or condition of, food with the potential
to cause an adverse health effect.

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Examples of Hazards…

1. Physical : Foreign material like hair, stone, dirt, metal, wood

2. Chemical : Oil, Grease, Pesticides, Toxins

3. Biological: Bacteria, Viruses, Moulds, worms, flies

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Sources of physical contamination

•People
•Packaging materials
•Machinery/Equipment
•Premises
•Pests
•Environment
•Raw materials
Sources of biological contamination

•Raw food
•People
•Equipment
•Air and dust
•Soil
•Pests
•Water
•food waste
Sources of chemical contamination

•Pesticides, preservatives, mould inhibitors

•Veterinary drugs
•Cleaning chemicals
•Food additives
•Perfume, scented soap
•Chemical reaction between metal and acidic food
•Machine oils
FSMS is

Rather than

Preventive and Pro active approach to control food safety

hazards.
FSMS Principles

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Hazard Analysis

The process of collecting and interpreting

information on hazards and
conditions leading to their
presence to decide which are
significant for food safety

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 Risk Assessment

Probability / Likely hood

High (3) Medium (2) Low (1)

Severity or Consequence

High (3) GMP

Medium (2) GMP GMP

Low (1) GMP GMP GMP

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Control Measure

Any activity that can be used to prevent , eliminate or reduce

to an acceptable level a food safety hazard.
What is a CCP?

A step where control can be applied and is essential to

prevent, eliminate or reduce a food safety hazard to
acceptable levels.
Determine the CCPs :

Modify Step
Q1. Are Control Measures Process or Is control at this step
in place for the hazard ? Product required for safety?
Yes No
Yes No

Q2. Does the Process Step

eliminate or reduce the Hazard Not a CCP
to an acceptable level ?
Yes No CCP

Q3. Could Contamination with

No Not a CCP
the Hazard occur at ,or increase Stop
to, unacceptable levels ?
Yes Critical
Q4. Will a Subsequent Process Control
Step eliminate or reduce the Point (CCP)
Hazard to an acceptable level ?
Yes No CCP
Not a CCP
Establish Critical Limit(s) :

• Establish target levels and tolerance which must

be met to ensure each CCP is under control

• Specify the criteria which MUST be met to ensure

that each hazard (which makes a Process Step a
CCP) is in “control”.

• E.g. Heating Temperature and time

• Double seaming effectiveness

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Establish a Monitoring system

• Establish a monitoring system to ensure control of the CCP by

scheduled testing or observations.
• Establish target levels and tolerance which must be met to
ensure each CCP is under control.
• Monitoring Procedures:
• What?
• When?
• Where?
• How?
• Who?

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Establish Corrective Action

• Establish corrective action, when a CCP is moving out of

control.
– Adjust the process to bring back under control
– Action plan for non conforming material

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Establish Verification Procedures :

Establish Verification Procedures,

consisting of:
- Verification of Monitoring
- Verification of Corrective
Action
Make practical plans for checking
whether the HACCP Plan is working
or not.

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Establish Documentation

Establish documentation concerning all procedures and

records

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 Case Study 3

In your groups, make a FSMS Plan for the process steps allocated
by the Tutor. Use flipcharts for presentation.

Preparation time: 45 mins

Presentation Time per group: 5 mins

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End of Session….

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