IV haccp.ppt

ISO 14000(ENVIRONMENT MANAGEMENT STANDARD)

• ISO 14000 standard is practical tools for the organisation that is not satisfied with mere compliance with legislation - which may be perceived as a cost of doing business. The standard is for implementing a strategic approach that can bring return on investment in environment related measures.

HACCP(FOOD SAFETY STANDARD)

• Food safety is a global concern. Not only because of the continuing importance for public health, but also because of its impact on international trade. Food Safety Systems shall therefore manage and ensure the safety and suitability of foodstuffs. HACCP is applicable for organisation, whether profit-making or not and whether public or private, carrying out any or all of the following activities : preparation, processing, manufacturing, packaging, storage, transportation, distribution, handling or offering for sale or supply of foodstuffs.

TS 16949(PARTICULAR REQUIREMENT FOR THE

APPLICATION OF ISO 9001:2005 FOR AUTOMOTIVE PRODUCTION AND RELAVENT

SERVICE PART ORGANISATION

• ISO 16949 specified, in conjunction with ISO 9001, the quality system requirements for the design, development, production and, when relevant, installation and servicing of automotive-related products. This technical specification is applicable to production and service part organisation. Where customer specified parts are manufactured, and can be applied throughout the automotive supply chain.

PS 9000(PHARMACEUTICAL PACKAGING STANDARD)

• The quality of packaging is a critical factor in assuring the safety and efficacy of medicines. Various problems may arise from inadequate quality range from the potentially disastrous mix-up of either cartons, label, leaflet, capable of causing patient harm, through seemingly minor cosmetic physical defect PS 9000 Pharmaceutical packaging material is an application standard which contains additional particular requirements, derived from GMP, that the pharmaceutical industry (in conjunction with its suppliers) has developed for the supply of packaging materials to the pharmaceutical industry.

BRC/IOP(FOOD PACKAGING STANDARD)

• The British Retail Consortium (BRC) and the Institute of Packaging (IOP) have developed this technical standard, to assist retailers and food manufacturers in the fulfillment of their legal obligations. The standard helps the protection of the consumers by providing a common basis for the audit of companies supplying packaging for food products to retailers.

ISO 9001/2000(QUALITY MANAGEMENT STANDARD)

• The introduction of ISO 9001:2000 has bought about a significant change in the way which organisations are required to operate their quality management system. By placing a clear emphasis on customer satisfaction, management systems now define quality through the eyes of the customers. Though the implementation of a process based approach there is a redical shift from system of conformance to a system of effectiveness. Finally, there is an emphasis on system development and improvement.

TO INCREASE

THE GLOBAL COMPETITIVENESS

OF INDIAN FOOD

PROCESSING INDUSTRY

QUALITYASSURANCE

IS MORETHAN

MANDATORY

PRODUCT QUALITY

• To boost business in food products, extra focus on food safety, product and process quality is a must.

• In fact, food safety is a major determinant of international trade in food.

• For ensuring processed product quality and safety, HACCP is recognised as in important tool.

HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)

• A system, which identifies, evaluates and controls hazards, which are significant for food safety.

WHY HACCP ?

• Build and improvemarket access in domestic and international trade through building sustained confidence in :

• (I) Institutional buyers.

• (ii) Importers.

• (iii) Buyers of intermediate products.

• (iv) Consumers and Government

WHY HACCP ?

• Reduction of losses due to rejection and recalls due to inconsistency in product quality.

HOW TO IMPLEMENT HACCP ?

• Demonstrate commitment by adopting simple tools of quality / safety management.

• Locate certified expert help to prepare Project report on HACCP and guide implementation.

• Train HACCP team amongst employees for implementation.

• Submit application in prescribed proforma for financial assistance from Ministry

DID YOU KNOW ? Ministry of Food Processing Industries provides

grant-in-aid to Indian food processing units for implementation of food safety and quality systems such as Total Quality Management (TQM) including Hazard Analysis Critical Control Point (HACCP), ISO 9000, ISO 14000, GMP, GHP, Financial assistance is available upto 33% of the total project cost subject to a maximum of Rs.10.00 lakh for General Areas and 50% to a maximum of Rs.15.00 lakh for Difficult Areas.

DOCUMENTS REQUIRED :

1. Application in prescribed format through State Nodal Agencies (Format available on website : http://mofpi.nic.in)

2. Certificate of incorporation/registration of the organisation.

3. Memorandum and Articles of Association and Bye Laws of the Society (if applicable)

4. Annual Reports/Audited Statement of Accounts of last three years.

5. Detailed projects report specific to implementation of HACCP/ISO 9000.

DOCUMENTS REQUIRED (CONTD) :

6. Sanction letter for term loan / working capital from banks / financial institutions.

7. Biodata/background of the office bearers/promoters of the organisation.

8. Information whether funding has been received/applied for from any other Government Agency.

9. Declaration and Certificate from the organisation that HACCP systems has not been initiated till the date of submitting the application to MFPI / State Nodal Agency.

For details / conditions,list of SNAs,

Please visit website :http://www.nic.in/mofpi

e-mail : [email protected]

For further details contact :Director, MFPITel : 2649 2248MINISTRY OF

FOOD PROCESSING INDUSTRIESGovernment of India

Punchsheel Bhawan, August Kranti MargNew Delhi - 110 049.

Written suggestions may be sent to : Joint Secretary, MFPI

Fax : 2649 7641

HAZARD ANALYSIS AND CRITICAL CONTROL POINT

What is HACCP?

• It is a difficult name for a simple and effective way to ensure food safety

• “HACCP” stands for HAZARD ANALYSIS AND CRITICAL CONTROL POINT SYSTEM.

• It allows you to predict risks to food safety, you will no longer have to rely solely on routine inspections to spot and control potential food safety hazards.

How will HACCP HELP YOU?

• Food safety is a key to good business. selling unsafe foods can cause illness, lost of sales and also customers. Safe foods means jobs, good business and happy customers.

• you probably already know that mussels may cause illness. As a mussel processor, you must understand the importance of food safety and also know that is your responsibility to provide safe foods. The HACCP system is the best way to keep the foods safe.

How will HACCP HELP YOU?

• the HACCP system has other benefits as well. HACCP focuses only on critical areas and thus saves time. HACCP makes inspections more useful by concentrating only on potential problems. Once you identify problems, you can easily correct them.

How will HACCP HELP YOU?

• Records produced for the HACCP system also have benefits. Tracking food temperatures and other data lets employees become interested in food safety. This interest can lead to better food handling, improved food quality and improved pride in their work.

IS HACCP NEW?• In the 1960 the Pillsbury Company

developed HACCP for foods as a part of its effort to produce foods for the space program. You can imagine how serious it would be if astronauts got food poisoning in space. So Pillsbury developed a system to predict and prevent food safety problems during food processing and handling

IS HACCP NEW?• Pillsbury’s system identified

potential problems with food safety in advance and set up methods to control each possible hazard. The company kept records to make sure the controls worked. With this HACCP safety system, Pillsbury made foods safe. Testing the foods for safety was unnecessary, the HACCP system prevented food safety problems.

IS HACCP NEW?

• Today, many food companies use the HACCP system to make sure their products safe. The U.S FDA, Dept. of Agriculture and Dept of commerce al encourage HACCP safety plans for food processing. This includes processing of aquacultured mussels.

THE SEVEN STEPS IN HACCP The major goal of any HACCP is

to prevent food safety problems from occurring. A HACCP food safety has seven basic steps. Each step is necessary for the overall program to work. The seven steps are:(1). identify potential food safety hazards (conduct the HAZARD ANALYSIS)

(2). Determine when and where to prevent problems (determine critical control points)

(3). set limits to control potential problems (establish critical limits)

(4). set up methods to monitor limits (establish monitoring limits)

(5). set up procedures to handle control problems (define corrective actions)

(6). use record keeping to check that control works (establish a record keeping system)

(7) .verify that the HACCP system works properly ( establish verification procedures)

Step:1- identify potential food safety hazards

HAZARD is any food property that may cause an unacceptable health to your customers. Hazards may be --• BIOLOGICAL including the presence of harmful bacteria, viruses or others.• CHEMICAL including toxins, heavy metals, drug residues, improperly used pesticides, cleaning compounds and or food additives.• PHYSICAL including foreign objects that may cause illness as metal, glass etc.

• HAZARD ANALYSIS (HA) when u do a HA, you determine the potential food hazards that are likely to occur in each processing steps. A HA also includes identifying preventive measures that control these risks.

• Food safety hazards can originate with in and outside the processing plant and can include hazards that can occur before, during and after harvest. A hazard that is reasonably likely to occur is one that a processor would control because there is a reasonable possibility that would occur without controls.

• Each food processing operation has its own unique potential food safety hazards. These hazards may vary from product to product and also from plant to plant.

Step:2- Determine when and where to prevent problems

In addition to determining the potential hazards, you may need to identify at what point in the food processing operation these hazards can be controlled best.

A CRITICAL CONTROL POINT (CCP) is a step in the product handling process where controls will reduce or eliminate hazards. CCPs should be designed to control food safety hazards that could be introduced:

(1). In the processing plant(2). Outside the processing plant

environment, including hazards that occur before, during and after harvest.

• Examples of CCPs might include:(1).Receiving(2).Chilling and cold storage(3).Thawing, mixing ingredients and

other food handling stages(4).Shipping

HACCP includes two major areas as

HAZARD ANALYSIS (HA) andCRITICAL CONTROL POINT (CCP).

Step:3- set limits to control potential problems

• Once you determine the CCPs, you may include critical limits that will reduce or eliminate potential hazards.

Examples of critical limits might include:(1).Purchasing specifications(2).Chilling and cold storage times and

temperatures(3).Handling practices

Step:4- set up methods to monitor limits

• Now that you have established limits for potential hazards, you must set up methods to be sure that are fallowed. These methods should include the procedures that will be used to monitor each and CCP, and how frequently the CCPs should be monitored.

Typical monitoring procedures include:(1).Visual observations (watching

workers practices, inspecting raw materials)

(2).Sensory evaluation (smelling for off-odors, looking for off-colors)

(3).Chemical measurements (ph, viscosity, salt content, water activity)

(4).Physical measurements (time and temperature)

(5).Microbial measurements (coli forms, Escherichia etc)

Step:5- set up procedures to handle control problems

Food safety problems occur when you don’t meet the HACCP limits. You must set up procedures to deal immediately with such failures. These procedures are called as “corrective actions”. Corrective actions ensure that:(1).No product enters commerce that is unsafe that.(2).The cause of deviation is corrected

Corrective actions need to be established for each critical limit at each CCP.Examples of corrective actions might include:(1). Rejecting products not meeting buying specifications(2). Adjusting cooler’s thermostat to get proper temperature.(3). Modifying food handling procedures(4). Discarding products.

Step:6- use record keeping checking that control works

• Monitoring results must be recorded for review by management. Record keeping is an essential part of HACCP system, these records indicate to management and government inspectors that you properly evaluated, handled and processed foods and ingredients.

HACCP records include documentation(1). Monitoring records include CCPs(2). Corrective actions taken(3). Calibration of process- monitoring

instruments(4). End product and in process testing

Step:7- verify that the HACCP system works properly Management must verify that the

HACCP plan is controlling food safety hazards that are likely to occur, and that the plan is being correctively implemented.

Verification includes:(1). An in-depth audit of the HACCP system at least once a year. Additional audits should be conducted whenever there are new products, new recipes or new processes. Each of this needs a new HACCP plan

(2). A daily record that ensures- (i). Controls and working (ii). Proper information was recorded. (iii). Proper corrective actions are taken (iv). Workers handled the food properly if records indicate potential problems, investigate immediately and document findings

(3).A routine review of consumer complaints to determine the need if they relate to CCPs or reveal unidentified CCPs.

(4). Calibration of process- monitoring equipment

(5).Period end product or in-process testing if needed.

•HACCP system should cover all foods. For most foods, this requires only common sense and knowledge of basic food handling practices. For multi ingredient foods, you may need technical assistance to develop a HACCP system

HACCP and SANITATION

•HACCP is an effective food safety management tool only when good sanitation practices are already in place. Without proper sanitation, HACCP cannot be effectively managed and improve food safety.

•Sanitation practices should be based on standard sanitation operating procedures, the FDA’s GMP regulations and on other applicable state and federal regulations including the FDA FOOD CODE 1995 and NATIONAL SHELLFISH SANITATION Program's manual of operation.

EXAMPLES OF PRACTICES THAT INCREASE POTENTIAL

FOOD SAFETY HAZARDS

CROSS CONTAMINATION• Storing of Raw foods with ready to eat

foods.• Employee practices leading to cross

contamination, such as handling products without washing hands and without gloves etc.

• Failure to properly clean the equipment.• Failure to adequately protect food from

contamination, such as sorting raw food from cooked food etc

• Improper disposal of refuse

IMPROPER COLD STORAGE

• Food stored at improper temperatures

• Coolers without thermostats• Poor cooling practices, overloading

the refrigeration units• Storage of food in improperly

labeled containers

OTHER HAZARDS

• Improper or inadequate cleaning and sanitation practices

• Poor food handling practices• Use of utensils and food contacting surfaces

that are made from improper materials• Inadequate documentation and record

keeping• Improper storage of chemicals and personal

items.

EXAMPLES OF CRITICAL LIMITS TO REDUCE OR ELIMINATE POTENTIAL

HAZARDS AT CCPs

CCP: RECEIVING

• Potential hazardous food at or below 400F

• Molluscan shellfish at or below 500F

• No evidence of spoilage, abuse, foreign objects or contamination.

CCP: CHILLING AND COLD STORAGE

• Do not leave potential hazardous food at room temperature

• Do not overload or stack containers in coolers

CCP: FOOD HANBDLING

• Covered by sanitation standard operating procedures and FDA’s GMP

• Use proper hand washing techniques• Use proper dish-washing and sanitizing

techniques• Cover and protect open cuts and

scratches • Use clean, sanitized we4quipment and

utensils• Stay home when sick

CCP: SHIPPING• Potential hazardous food at or below

400F• Molluscan shellfish at or below 500F