Food Safety Training

Titan Frozen Fruit

Purpose of Training
 Food Safety = Consumer Safety
 FDA Regulations
– 21 CFR Part 110 (GMP)
– 21 CFR Part 120 (HARPC – Hazard Analysis and
Risk-Based Preventive Control)
– Bioterrorism Act
 Audits
– Customers
– Regulatory Agencies
– 3rd Party Auditors
 Agenda
 Food Safety and Quality Policy
 GMP (Good Manufacturing Practices)
 HACCP (Hazard Analysis and Critical Control Points)
 HARPC (Hazard Analysis and Risk-Based Preventive
Control)
 Food Allergens
 Food Terrorism/Food Defense
 Quiz
Food Safety and Quality Policy
Titan Frozen Fruit makes a commitment to its
customers; that all products produced are safe
and of the highest quality. Our Senior Management
supports the continuous evaluation of its processes to
identify opportunities for improvement in the interest of
meeting or exceeding customer expectations and
government regulations. We will accomplish this through
full utilization of our HACCP and Quality Programs and
providing our employees with the resources, including
information and training to successfully ensure the
safety and quality of our products. In addition where
improvements to our facility and equipment can
contribute to accomplishing these goals, we will invest in
making these changes and strive for continuous
improvements.
 GMP
Good Manufacturing Practices
Purpose of GMP’s

 Prevent The Possibility of Contamination

– Keep out rodents, birds, insects, etc.
– Keep out objects, paint chips, metal, rust, etc.
– Prevent microbial contamination
– Prevent contamination by chemicals, lubricants
– Prevent cross contamination from allergens
– Promote food cleanliness
If we do not comply, we might suffer
these consequences:
 Fines
 Product Seizure
 Bad Publicity
 Illness
 Plant Closure
 Prosecution
 Jail
GMP – Personal Hygiene Practices
Hair
Hairnets must be worn in the plant
The hairnet should cover all exposed hair
and ears
A beard net is required for full beards,
moustaches, goatees, and generally any time
it appears you have not shaved in a few days.
The beard net must cover all facial hair.
GMP – Personal Hygiene Practices
Protective Clothing
 Uniform and/or disposable aprons, sleeves,
must be worn and changed as necessary
when working with food or next to food
contact areas
 Work clothes must be kept reasonably clean
and in good repair
 Pens, tools and other objects must be
removed from pockets above the waist.
GMP – Personal Hygiene Practices
Jewelry
 No watches or bracelets
 No necklaces
 No rings except plain wedding bands
 No earrings, nose rings, eye brow studs, tongue
studs
 Jewelry must be removed before entering the
Main Plant including the storage warehouse.
GMP – Personal Hygiene Practices
Hands
 Hands must be washed and sanitized at
any time they may become soiled or
contaminated
– After lunch, break…
– After using the bathroom….
– After touching the floor, trash can…
– After touching face, nose, ears, forehead…
– *Wash hands before putting on gloves
GMP – Personal Hygiene Practices
Hands
 Keep hands and fingernails clean
 Nail polish, false fingernails, and false
eyelashes are prohibited.
 Band-aids cannot be worn without a
protective glove covering them. Blue, metal
detectable band-aids issued by Titan Frozen
Fruit must be used to cover wounds.
 Personnel with cuts on their hands or any
other part of the body that may pose a
contamination risk shall not work with or near
exposed product areas.
GMP – Personal Hygiene Practices
Gloves
 Clean nitrile gloves must be worn at all times
when handling food items and product
contact packaging
 Gloves must be cleaned and sanitized before
handling food items and product contact
packaging
 Change gloves when torn
 Clean and sanitize gloves after touching
garbage, after touching face, nose, ears,
forehead or any other objects that may pose
a contamination risk.
GMP – Personal Hygiene Practices
Conduct
 Eating, Gum Chewing, and Drinking in the plant
is prohibited
 Employees shall not hold toothpicks,
matchsticks or other objects in mouth
 Smoking or chewing smokeless tobacco is
prohibited inside the plant
 Coughing or sneezing must be directed away
from product and must be blocked by shoulder
or upper arm.
GMP – Hygienic Handling of Products
Illness
 Report to your supervisor if you have
communicable disease or infected
wounds – you should not be working in
the processing area if you do.
 List of Infectious Diseases:
www.cdph.ca.gov/pusforms/forms/pages/
CD-Report-Forms.aspx
Food Allergens
Food Allergen Reaction
 Effect of a Food Allergy Reaction
– Anaphylaxis (severe allergic reaction)
– Symptoms can range from mild (e.g., hives,
stomach sickness) to severe (e.g., swelling
of the throat, loss of consciousness)
– On-set of symptoms can be several minutes
to a couple of hours
– Quantity of allergen leading to a reaction
can be small < 10 ppm
 Effect can be FATAL
Food Allergy vs. Food Intolerances

 Food Allergy is a true allergic reaction.

Body fights exposure to the allergen
with inflammation.
 Food Intolerances such as “allergic to
milk” or “allergic to tomatoes” are not
true allergic reactions. Usually a much
milder reaction in stomach. Rarely fatal.
Usually causes vomiting.
The BIG 9 Food Allergens
 WHEAT
 DAIRY
 EGGS
 SOY
 PEANUT
 TREE NUTS
 SHELLFISH
 COCONUT
 SESAME
Titan Frozen Fruit Allergen Policy
 We do not use Allergens in our plant
 GMP’s and Vendor Approval
Procedures prevent Allergens in
process area
– Food is not allowed in processing area
– Employees must wash hands and adhere
to glove policy in food contact areas
 All new ingredients must be properly
screened/approved for Allergens
HACCP & HARPC
Hazard Analysis and Critical Control Point
Hazard Analysis and Risk Based
Preventive Control
Purpose of HACCP
 To prevent, eliminate, or reduce the
following food safety hazards:
– Biological
– Chemical
– Physical
 Focus on hazards that are severe and likely
to occur
 Will someone get sick or injured if this hazard
is present?
HACCP Plan Development
 The HACCP system is built upon a foundation of
pre-requisite programs
 There are 5 preliminary tasks to developing
HACCP plans and 7 guiding principles
 Generate separate HACCP plans for each
product and process
 Hazard analysis must consider practices and
processes from harvest to consumption.
HARPC
 On January 4, 2013, the FDA issued a
proposed rule implementing the hazard
analysis and risk-based preventive control
(HARPC) provisions of the FDA Food Safety
Modernization Act (FSMA). The proposed
rule applies to certain unintentional hazards –
e.g., microbiological, chemical, physical or
radiological hazards – that may occur at a
food facility that manufactures, processes,
packs or holds human food.
The HACCP Team

 HACCP team leader

 Team shall be inter-departmental
 Team members are formally trained by
a qualified 3rd party agency
 Conducts monthly internal audits with
corrective actions
 Titan Frozen Fruit
HACCP Team
Andy Nunez, Director of Quality Assurance (Team Leader)
Eric Duyck, Vice President of Operations
Al Souza, Director of Operations
Nilo Diaz, Sanitation Manager
Sergio Hernandez, Director of Engineering and Maintenance
Humberto Ramos, Quality Assurance Manager (In Training)
Evan Schubert, Document Control Specialist (In Training)
Fidel Perez, Maintenance Manager (In Training)
Tommie Gausse, Continuous Improvement-Process Engineer
 Titan Frozen Fruit
HACCP Plan Example
IQF Whole Strawberries
 Product Description
 Flow Diagram of Process
 Hazard Analysis
 HACCP Plan
CCP’s
Critical Limits
Monitoring Procedures
Corrective Action
Verification
Record Keeping
HACCP Change Management
 Now that your HACCP plan is in place,
nothing related to HACCP can be changed
without the prior approval of the HACCP
Team.
 can’t remove a metal detector, change
settings, or timing of checks
 can’t remove a screen
 can’t change forms for monitoring
 Change requires signature of 3 of HACCP
Team Members.
HACCP Training
 Annual training review is required for the
HACCP team
Q: What are “CCP’s” ?
A: Critical Control Points such as metal detector and
pasteurizer.

 Annual CCP training review is required if you

use and document:
– Metal Detection
– Pasteurization Time and Temperature
– Finisher Screens
“Food Terrorism” & Food Defense
What is Food Terrorism?

 World Health Organization, 2002

– An act or threat of deliberate contamination
of food for human consumption with
chemical, biological, or radionuclear agents
for the purpose of causing injury or death
to civilian populations and/or disrupting
social, economic or political stability
 Who are we concerned about?
Internal
Disgruntled employees
Members of terrorist groups posing as
employees

External
Organized terrorist or activist groups
Criminals/Subversives
Why are we concerned about
food terrorism?
 Could cause significant economic and
psychological damage
 Likelihood of intentional acts increases
with new extremists/radical groups
wanting to cause harm to the public
 Everyone eats and drinks!
Intentional Attacks and Threat
 1984 – Oregon – Rajneesh cult
– Salmonella placed in salad bars at restaurants,
attempt to sway results of a local election. 751 ill,
45 hospitalized

 1989 – Chile –terrorist group

– Phone call to U.S. Embassy claiming to have
contaminated Chillean grapes with cyanide
– Ruined the crop and Chilean fruit sales for an
entire season, at a cost of $200+ million
Bioterrorism Act of 2002

 Goal: to improve capacity to prevent,

detect, and respond to terrorist acts
– Allows for:
• Administrative detention
• Registration of food facilities
• Maintenance and inspection of records
• Prior notice of import shipments
Food Defense Program
 Measures we can put in place to counter food
terrorism
 Components
– Personnel
– Perimeter security
– Facility security
– Receiving and transportation procedures
– Ingredient assessment (Vendor Approval)
– Process security
State Regulatory Guidelines
Controls – Facility Integrity

 Secure all doors to facility. No one

enters without authorization.
 Doors are not just closed for insect and
dust anymore. Prevention of entry of
people.
 Examples of changes: Locked gates,
fences, badges, escorts.
Controls - People
 Background/reference checks for new
hires.
 Visitors should be escorted from guard
desk.
 Badges, particularly important for
unfamiliar faces.
Controls – Incoming Material

 Known origin of materials.

 Truck seals examined.
 Truck inspections conducted.
Controls - Manufacturing
 All containers need to be tagged / labeled
with correct lot identity.
 Usage of materials must be letter perfect.
 Accuracy of records is very important.
 Traceability – Extremely important. May
impact people’s lives.
 Be sure container lids are closed when
not in use to reduce possible tampering.
What can YOU do?
 Be alert for potential tampering.
– Torn bags, missing truck seals.
 Be suspicious of unfamiliar people in
your area. Look for a badge or ask
questions.
 If you are unsure of a person notify your
supervisor or QA immediately.
 Help control any easy access to the
building. Close doors.
What can YOU do?
 Be accurate in record keeping for
traceability
 Keep containers and bins closed
 You are the eyes and ears of prevention

 Don’t make it easy for an “event” to

occur
QUIZ Time – Good Luck!