Professional Documents
Culture Documents
16-09-2022
Educate employees on the Product
Safety & GMP Principles
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Product Safety is NOT the same as Plant Safety
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Food safety is used as a scientific
method/discipline describing handling,
preparation and storage of food in the way that
prevent food-borne illness which can cause
injury/illness/ or death
Food Safety Regulations include:
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The Food Safety Code requires that
you:
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Hazard Analysis and
Critical
Control Points (HACCP)
A preventive approach to food
safety from
biological, chemical, and
physical hazards
in the production process that
can cause
the finished product to be
unsafe.
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Biological Hazards: harmful bacteria, viruses
or parasites.
Sources: skin, nails, sores, clothing
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Chemical Hazards: compounds that can cause
illness or injury due to exposure.
Sources: cleaning agents, pest sprays
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Physical Hazards: foreign objects that can
cause harm to product.
Sources: glass, jewelry, food
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Good Manufacturing Practice (GMP)
A system for ensuring that products are produced
and controlled according to quality standards.
GMPs:
Require employees to understand the aspects of
product safety.
Requires employee’s commitment to perform their
jobs as trained and always comply with GMP Rules.
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Hair nets and beard
nets must be worn.
If you have hair on your head or
face, you need to cover it!
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No Jewelry or watches
(plain wedding band and medical bracelets
are allowed).
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No false
eyelashes, false
nails, strong perfume,
jewels, no nail
polish.
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In production…
No…
Chewing gum or tobacco
Spitting
Eating
Candy, mints, cough drops
Cell phones
Audio headsets
Water bottles
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(No glass or ceramic types of containers are allowed).
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Hand Washing is required after:
Visiting the restroom
After coughing, sneezing, using a tissue, using tobacco,
eating, or drinking
After touching bare human body
parts other than clean hands
Working on machinery
Handling garbage
Returning from breaks
or lunch
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Hand Sanitizer
Hand sanitizer must be used
Located in every production and
throughout the facility
Required every time an
employee* enters a production
line before contact with product.
*Employee means ALL employees
(packers, leads, supervisors, quality, process
technicians, process assistants, maintenance,
engineers, etc.)
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Employees with visible cuts, infected cuts,
boils, or sores are not permitted to handle raw
or finished product unless properly covered
with a colored bandage.
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Lockers and designated personal
storage bins are provided for
storage of employee’s personal
items.
• Not allowed
Food or drink
• Allowed
Keys, pens, notepads,
jackets
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Employee must wear ear
protection, safety shoes and helmet
in the production area.
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Clothing
No…
Items in shirt pockets
Clothing that exposes lower torso
Belts with extra parts or big
buckles
Clothing with glitter, jewels,
sequence, etc.
Items behind held behind ears,
in hair, or attached to shirt collar
Clothing should be clean and in
good repair.
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Smoking
To prevent smoke from entering the facility and
contaminating product, there are 2 approved
smoking areas:
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Trash
Bags of garbage are not allowed on the production
or warehouse floor
Garbage must be held in a approved and labeled
container
Lids must remain closed on garbage containers and
dumpsters
Use rag containers must remain closed
Garbage from the break room must
be taken directly to the dumpsters
No garbage on tool carts, racks, or equipment
Do not use product cases as garbage collectors
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Many, many buckets…
Blue buckets – recyclable clean lids
only
Red buckets – maintenance items
Yellow buckets – Raw material &
regrind labeled for contents
Grey buckets – Product which has
made contact with the floor or otherwise
deemed as dirty
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Labeling for identification
Plastic rolls
Byproduct bins/bags
Buckets
Packing tables
Finished product
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Glass & Brittle Policy
Report any broken or cracked
glass and plastic to the Supervisor and
do always inspect.
Sight glass of equipment
Lights
Window and doors with glass
Other part of machine with glass
Plastic containers used
Plastic material installed on machine
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Cleaning Color Code Program
All mops, brooms, shovels, air hoses,
dust pans, etc. must be stored off the
floor and
labeled for
their
approved
area of use.
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Cleaning & Sanitation Program
Cleaning and sanitation must be practiced to avoid
contamination of product. Areas included in the cleaning
program:
Break room
Garbage areas, facility ground
Restrooms
Floors, walls, ceilings
Fans, lights
Production equipment
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Documentation
All departments must maintain proper
documentation and records.
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Summary
Know you product safety policy
Be familiar with standard requirement
Follow procedures that apply to your job
Document your activities
Look out for product hazards in the facility
Follow GMPs at all times
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RS 184: 2017
September 2022
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Clause 1 Scope
Clause 3 Definitions
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Product Safety Hazard –
chemical,
biological or
physical agent in the product or condition of the product
with a potential to cause quality defect or an adverse
health effect.
Reduces Dependence On Finished Product Sampling &
Testing
Hazard Analysis And Critical Control Points
It Uses A Preventive Approach To Food Safety
ORIGIN OF HACCP
From the NASA work, Pillsbury developed the
philosophy
Resources,
implementation:
Management shall provide necessary resources (time, competent personnel,
suitable and adequate infrastructure, work environment, equipment and
funding)
Appropriate records of education, training, skills and experience shall be
maintained
Effectiveness of training shall be evaluated
5.6 Communication
Effective arrangements for communicating internally and externally (suppliers,
customers
Issue : Apr 2020 and regulators) on issues having an impact on food safety.
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team meetings
Distribution conditions
Shelf life
Safety
Stage 3. Identify the intended use
Direct consumption or further processing
Misuse or abuse
infants…
Stage 4.Construct a process flow diagram
Details of all process activities:
Inputs into the process in terms of raw materials
Product-in-progress
Rework
Rejected products
Stage 5. Arrange an on-site confirmation of the flow diagram
Confirmation shall be done the HACCP team
Confirmation process flow diagram is done through
conducting on-site:
Sample activities
Interviews
CCPs are steps in the process flow where Significant hazards are
Records
.
List of product ingredients and associated materials
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
Hazard Analysis processes
Mixing
Etc….
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
2 ISO 22000:2018
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
2 ISO 22000:2018
If R is 1- 2 Negligible (NS)----------PRP
3-4 Minor impact (NS)-------OPRP
6- 9 Major impact (S)……….CCP
12- Severe impact (S)……….CCP
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
2 ISO 22000:2018
R=L×C(S)
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
2 ISO 22000:2018
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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Not Hazard
CCP control at
step……
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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8.5.3 Validation of
control measure(s) and combinations
of control measures
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
Process Step CCP No Hazard Critical Limit Control Monitoring Monitoring Corrective Responsible
Measure Frequency Action
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Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
Establish Critical Limits
A value of physical, chemical or biological
nature which separates acceptability from
unacceptability.
CL indicate absolute tolerance for safety.
Critical limits are not necessarily equal to
existing processing parameters.
Criteria often used include measurements of
temperature, time, moisture level, pH, activity
of water, available chlorine, sensory
parameters.
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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DISPLAY CRITICAL LIMITS NEXT TO CCP’s
HOW TO SET CRITICAL LIMITS
> PUBLISHED DATA > EXPERIMENTAL DATA
> EXPERT ADVICE > MATH. MODELLING
--------------------------------------------------------------------
INDICATE ABSOLUTE TOLERANCE FOR SAFETY
CRITICAL LIMITS NOT NECESSARILY EQUAL TO EXISTING
PROCESSING PARAMETERS
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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PURPOSE:
The purpose of this workshop is to practice using an appropriate framework in
conducting hazard analysis and drafting a HACCP Plan and an OPRP plan for an
organization
INSTRUCTIONS FOR DELEGATES:
Form teams of 3-5 people per group.
Choose one of these Processes/activities
Storage of raw materials
Transportation of finished
Purchasing of raw materials
Using the formats provided, name at least four hazards that must be addressed to
ensure food safety and analyze/assess them.
Using the format provided prepare a draft HACCP Plan for the organization
Using the format provided prepare a draft OPRP plan for the organization
Prepare to share your work in class.
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
RECAP: Hazard control plan must contain, as a minimum,
the following information for all identified CCPs and
OPRPs:
what food safety hazard are you controlling with this CCP or
OPRP
what measure have you put in place to do so
the critical limit/s or action criteria in place that can’t be
exceed
how do you monitor this activity
which corrections and corrective actions will be carried out
if critical limits or action criteria is not met
who is responsible for this activity (defined responsibilities
and authorities)
what records do you maintain as monitoring evidence
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
Following the establishment of the hazard control plan, the
organization shall update the following information, if
necessary:
a) characteristics of raw materials, ingredients and product-
contact materials;
b) characteristics of end products;
c) intended use;
d) flow diagrams and descriptions of processes and process
environment.
The organization shall ensure that the hazard control plan
and/or the PRP(s) are up to date.
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING