FOOD SAFETY & HACCP Awareness Program

For

M/s. Pepsico India Holdings Pvt. Ltd. Dharwad

Suhas Bedekar SGS India Pvt. Ltd.

THE SGS GROUP

Expertise, Everyday, Everywhere ...
SGS established in 1878 as French grain shipment inspection house, registered in Geneva as SGS (Socit Gnrale de Surveillance) in 1919, is the clear global leader and innovator in inspection , verification , testing and certification company. SGS is recognized as the global benchmark for quality and integrity. Represented in over 140 countries 1,260 offices 365 laboratories 46,000 full time employees

With Global capability at your service

Europe
422 offices 115 laboratories

North America
100 offices 105 laboratories

Asia - Pacific Africa Middle East

212 offices 54 laboratories

Latin America
98 offices 30 laboratories

137 offices 39 laboratories

2007
Certification Bio Sciences / Environment Services to Insurance Industry Services to Govt. & Institutions Industrial & Consumer Products Testing Petrol & Petrochemicals Minerals

1878

Agriculture

We provide leading & innovative services

Certification Inspection
In the areas of

Verification Outsourcing Risk Management Testing & Analysis Training

SGS in India

Founded in 1950 Headquarters in Mumbai ISO 9001:2000 Certified 35 offices 17 Laboratories Nearly 2700+ people

To all industries
Agriculture Automotive Consumer Products Environment Government & Institutions Industrial Life Sciences Minerals Oil, Gas & Petrochemicals Systems and services certification

An Real Life example of what happens to a company. That did not understand the importance of FOOD SAFETY.

Food Safety Incidents in Asia

Milk company profit plummets from US$ 84 M to a loss of US$ 442 M. In excess of 14,700 consumers with food poisoning.

Snow Brand (Japan)

June 28, 2000 June 29, 2000 July 22, 2000

Product Recall Requested Product Recall began More than 14,700 consumers affected with Food Poisoning Brand sales dropped by 80%

Aug 5, 2000

How did all this happen?

Insight can only suggest why it happened: The recession of the 1990s forced cost cutting measures Staff retrenchment - lost people with experience
Inadequate staff training Temporary equipment used permanently (no CIP system) No technical support guidelines Product recycled

Records were not accurate avoidance of blame Decision making was delayed

What was the direct cause of the crisis?

Power failure resulted in holding milk at plus 30 deg C. Staph.aureus grew and produced Enterotoxin A
100 200 ng will cause illness 1 glass of low fat milk containing the tainted powder would have contained between 80 160 ng of Enterotoxin A

Warm milk processed into powder and finally used for making milk.

THE FOOD SAFETY AND STANDARD ACT : 2006

OBJECTIVES OF THE ACT

1. To consolidate all the laws related to foods, standards and enforcement agencies 2. To establish the Food Safety and Standards Authority of India, for (a) laying down science based standards (b) regulating manufacture, storage, distribution sale and imports by strengthening existing enforcement mechanisms (c) ensuring availability of safe and wholesome food for human consumption (d) making provisions for graded penalties (e) shifting from regulatory regime to self compliance employing FSMS

OBJECTIVE 1: INTEGRATION OF VARIOUS LAWS AND ORDERS SPECIFIED IN THE SECOND SCHEDULE (SECTION 97)
1. 2. 3. 4. 5. 6. 7. 8. 9. The PFA Act (No. 37 of 1954) The Fruit Product Order, 1955 The Meat Food Products Order, 1973 The Vegetable Oil Products (Control) Order, 1947 The Edible Oils Packaging (Regulation) Order, 1998 The Solvent Extracted Oil, De-oiled Meal and Edible Flour (Control) Order, 1967 The Milk and Milk Products Order, 1992 Any other order issued under the Essential Commodities Act, 1955 relating to food Any other law in force in any State upon Commencement of this Act shall stand repealed

OBJECTIVE 2: ESTABLISHEMNT OF ENFORCING AUTHORITY Central Government Food Authority

23 members

Enforcement

Scientific Committee Scientific Panels 8+

Central Advisory Committee

47+11+3=61

CEO (Addl. Secy ) Sectt.

Designated Officer (SDO rank) Licensing Officer

State Food Safety Commissioners

Chairperson

Food Safety Officer Food Analyst

SCOPE OF THE ACT

primary foods (produce of agriculture, horticulture, animal husbandry, dairying, aquaculture); genetically modified foods and organic foods; infant foods; pre-packaged commodities; packaged drinking water; caterers; alcoholic drinks; chewing gums; substances and water used in the preparation of foods; food additives of all kinds.

EXCLUSIONS FROM THE ACT

Animal feed Live animals (not placed for marketing for human use) Produce of the farmers and fishermen at farm level Plants prior to harvesting Drugs Medicinal products Cosmetics, narcotics or psychotropic substances

UNSAFE FOOD MEANS

article of food or its package, composed wholly or in part of poisonous or deleterious substances; consisting wholly or in part any filthy, putrid, rotten, decomposed or diseased animal substance or vegetable substance; processing under unhygienic conditions or presence of harmful substances; substitution with any inferior or cheaper substance; presence of unpermitted additives, preservatives, colours, flavours, etc.; part or full abstraction of any constituent (adulteration); presence of worms, weevils or insects and extraneous matter; misbranded or concealed or unidentifiable foods; containing pesticides and other contaminants in excess of quantities specified by regulations; Best before date expired.

MANDATORY IMPLEMENTATION OF FOOD SAFETY MANAGEMENT SYSTEMS

(Time Frame requested by Food Industry Associations for adoption *)

Sector Small and Medium Scale, 3 Star Hotels Large Scale, 4 and 5 Star Hotels

FSMS GHP & GMP HACCP

Time 5 yr 4 yr 2 yr

Tiny Scale/Street Vendors GHP

* In response to Draft Notification GSR No. 578 dated 20.9.2006 by MOH. Two month period was given to send the comments o MOH

NOW ISNT THE TIME TO THINK ABOUT FOOD SAFETY & QUALITY

PUBLIC ACCEPTANCE
Needs Safety & Quality

Then Is it acceptable ?

Physical Hazard with Pizza

Hair is complimentary

Do You Know what is behind the bread served beautifully in hotels in the basket ?????

Food Safety / HACCP with SGS

The Need
Major food scares, poisoning, GMOs, chemical residues have all highlighted the imperative to;
Manage risk across the entire food chain (A paddock to plate approach) Move from the old end of line product inspection approach (often by government inspection agencies) to a new environment of quality assurance approach where the supplier assumes responsibility for safety.

BRAND PROTECTION

The Answer
An Integrated company-wide Quality Management System that; Manages food safety issues Builds in customer product quality requirements Meets regulatory & market requirements Is cost effective and makes money

Why Protect Customers

It is illegal to be unsanitary Very Young and the elderly are more susceptible Good food protection lowers costs Good sanitation promotes repeat patronage

Key Points
All food service establishments have the potential to cause foodborne illness Errors can occur at any stage : purchasing, receiving, storing, preparing, serving, cooling, and re-heating Most victims of foodborne illness do not readily identify the source.

What is Driving Food Safety

Customers / Increased incidents of Food Borne Illness Regulatory Bodies (Governments) Food Bill World Health Organization (CODEX) Market Access (EU / USFDA ) Shareholders, Insurers (Litigation/Claims) Retailers&Private Labels (Brand Protection)

Food Safety Issues Bangkok Post Sept. 1996 - Pesticides Laced Vegetables Mar. 1996 Mar.2002 - Preservatives - antibiotic in prawn/chicken meat

Never has Food Safety come under such scrutiny. Regulators are increasingly active in safeguarding food. Globalisation and dismantling of trade barriers means suppliers have to compete on equal terms. Customers are better educated and informed and are demanding:
Safety Consistency of quality Value for money

FOOD SAFETY ELEMENTS

Interactive communication

System management

Prerequisite programs

HACCP principles

Causes of Food Safety Problems

PEOPLE

FOOD

FACILITIES

The Major Causes of Food Borne Incidence are;

Supply of poor quality raw materials Mishandling raw materials Change in formulation of product Change in the process of product Cross-contamination Inadequate cleaning Inadequate maintenance Addition of the wrong ingredient

Cross- Contamination
HandsRaw food- Ready to eat food

Food contact surfaces Cleaning Cloths, sponges Touch or drip fluids

Your Challenge To Prevent Outbreaks:

Number of foods at risk Multiple chances of food to be contaminated Types of Customers - Children, Elderly Shortage of trained Employees High Employee turn-over

SO LET US MAKE A BEGINNING

G. Modified Crops Lack of Awareness

Pesticides Chemical Fertilizers Process Out-of Control

Food Safety

Wrong Mark/Label

RISK
Artificial Quality System

Package Failure Transportation Damage Storage Damage

Unhygienic conditions

Superficial Quality Checks Restricted Substances

HACCP
Hazard Analysis and Critical Control Point

Is HACCP .

H A C C P

- Hard! - Agonizing! - Confusing! - Complicated! - Paper work!

It Is NOT

HACCP stands for

H - Hazard A - Analysis C - Critical C - Control P - Points

HACCP
A system for Food - Safety Control

Benefits of HACCP
Systematic approach to Food Safety Proactive and Preventive management system Complements and strengthens the QMS Internationally recognized Fewer rejects Cost Effectiveness Increased confidence / customer satisfaction Risk Management Tool Brand Protection Improves Team work and motivation Regulatory Requirements

HACCP IS
Not a zero-risk system, it is designed to minimize the risk of food-safety hazards. A management tool used to protect the food supply chain and production process against microbiological, chemical and other physical hazards contamination.

Origin of HACCP
Pioneered in the 1960s. First used when foods were developed for space program. Adopted by many food processors and the U.S. Government.

Hazard
A biological, chemical or physical property that may cause the food to be unsafe for consumption

BASIC REQUIREMENTS FOR HACCP SYSTEM

HACCP Identifies Hazards Biological Chemical Physical

Bacteria may be
Pathogenic (Diseases)

Toxicogenic (Food Poisoning)

To Grow Bacteria Need F A T T O M

Food (Nutrients) Acidity (pH >4.6) Temperature (4-60 deg C) Time (cell double every 20 minutes) Oxygen (aerobes + , anaerobes -) Moisture (Aw >0.85)

Temperature

Bacteria which cause food poisoning prefer to live at human body temperature which is 37C.

TEMPERATURE

Danger Zone

4 C

65 C

WATER ACTIVITY (Aw)

0.5 0.6 0.7 0.8

Soft Cheese 0.9

0.2

0.3

0.4

1.0

Water Potentially Hazardous Foods Aw > 0.85 Dried Noodles Jams Jellies

Meat/Poultry

Bananas
Commercial Mayonnaise

1 pH Scale

14

Limes, Lemons

Water

pH : Bacteria do not grow well at a pH < 4.6

HACCP Training

BINARY FISSION

GIVEN IDEALCONDITI ON BACTERIA ARE ABLE TO DIVIDE INTO TWO EVERY 10-20 MINUTES

1 Bacteria Becomes 7 hours 20 Lakhs , 8 hours 1 Crore70 Lakhs ,9 hours 13 Crores Looks Impossible , But True, See How
Minutes 0 20 40 One Hour 80 100 Two Hours 140 160 Three Hours 200 220 Four Hours 260 Number 1 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192 Minutes 280 Five Hours 320 340 Six Hours 380 400 Seven Hours 440 460 Eight Hours 500 520 Nine Hours Numbers 16384 32768 65536 131072 262144 524288 1048576 2097152 4194304 8388608 16777216 33554432 67108864 134217728

The PHASES of Bacterial Growth

Stationary Decline Log

No. of Cells

Lag Time

Virus
Hepatitis A and E Norwalk Virus Group Rotavirus

VIRUS
Contaminate food through poor personal hygiene contaminated water or through shellfish Can cause serious illness such as hepatitis A

PARASITES AND FUNGI

Parasites are micro-organisms that need a host to survive Can be killed by thorough cooking or freezing Molds - usually microscopic - colonies can been seen as fuzzy growths Yeasts - need sugar and moisture - appears as bubbles or slime

TOXINS FISH TOXINS

Puffer fish, moray eels, and freshwater minnows contain natural toxins Amberjack, barracuda and large snappers can carry Ciguatoxin (Ciguatera)

PLANT TOXINS
SOME MUSHROOMS JIMSON WEED AND WATER HEMLOCK JELLY MADE FROM APRICOT KERNELS

COOKING OR FREEZING DO NOT DESTROY ALL PLANT TOXINS

CHEMICAL HAZARDS
These are chemicals in the food which will cause:

Illness if ingested Poisoning Accumulate in body tissue Long term health disorders

CHEMICAL HAZARDS
Pesticides Food additives and preservatives Cleaning and sanitizing chemicals Toxic metals Lubricants used on equipment Personal care products Paints

CHEMICAL HAZARDS
The following table lists some of the different types of chemicals hazards:
Mold Toxins Aflatoxin Histamines Agricultural Chemicals Pesticides Antibiotics Insecticides

Detergents Lubricants

Food Additives Preservatives (Nitrites) Flavour Enhances Colour Additives

Unintentionally or incidentally Added chemicals:

Agricultural Chemicals (e.g.., pesticides, fungicides, herbicides, fertilizers, antibiotics, and growth hormones) Prohibited substances Toxic elements ( lead, Zinc, arsenic, mercury, cyanide) Secondary Direct and Indirect - Plant Chemicals (e.g., lubricants, cleaning compounds ,sanitizers, paint)

Physical Hazards
Any potentially harmful extraneous matter not normally found in food

PHYSICAL HAZARDS
These are foreign objects which may cause:
Trauma Injury Illness The customer to think poorly of your products

PHYSICAL HAZARDS
Metal from machines Hair in food Glass pieces in ice Plastic pieces from stocking crates Wood from shipping crates Insect droppings in rice, wheat

PHYSICAL HAZARDS The foreign materials most commonly found in foods are:
Material Wood Glass Stones (Pits) Plastic Metal Bone Insects Hair Jewelry Likely Sources Utensils, Pallets Lamps, Bottles Dried Fruits, Vegetables Packaging Machinery Meat Everywhere Staff Staff

QUALITY HAZARDS
Is a term used to encompass environmental Hazards, animal welfare hazards, occupational and safety hazards, as well as failure to meet customer requirements.

Quality hazards do not cause sickness to the consumer But sickens the company

Examples of Quality Hazards:

Wrong protein levels in wheat Oranges with blemishes Potatoes of the wrong size Bread that has been over baked A meal in a restaurant that has been poorly presented The bottom falling out of a meat pie Product specifications not met, i.e., size, shape, texture, smell

Pre-requisites
GMP - Good Manufacturing Practices SSOP - Sanitation Standard Operating Procedure HACCP - Hazard Analysis and Critical Control Point

PRE-REQUISITES
GMP is a Sound Foundation for Food Safety GMP provides independent certification and verification that the basic pre-requisite GMP necessary for an effective HACCP food safety program are being followed. GMPs are minimum common sense sanitary and processing requirements applicable to all food processing establishments. They provide the basic foundation for the development of an effective food safety & quality management system. Many food industry sectors have implemented GMP for food processing as the foundation upon which they have developed and implemented other food safety & quality management systems, such as HACCP, SQF 2000cm and/or ISO 9000.
HACCP GMP or HCE Food Hygiene Training

Good Manufacturing Practices

Personal Hygiene Building and Facilities Plant and Ground Sanitary Operations Sanitary Facilities and Controls

Good Manufacturing Practices

Equipment and Utensils Process and Controls Warehousing and Distribution

GMP COMPONENTS
Buildings and facilities Equipment and utensils Production and process controls

BUILDING EXTERIOR:
Design, Floor, Windows, Animals, Glass, Drainage. Lighting Air Quality, Ventilation, Air Filters, Dust Collectors, Positive / Negative Pressures Waste, Drains, Sewage, Waste Collectors

A big no to this

BAD-House keeping

A big no to this

BAD-Broken tiles-accumulate waste

BAD-Roof leaking and causing untidiness

BAD-Open door leads to pests

Is it dangerous for products ?????

Good and Bad

BAD-Steam leakage-Energy loss

BAD-GMP

GOOD-Preventive practices

Is it Right way to keep clean uniforms

Is it right way to keep

Aisa Kyo Hota Hai ???????

BAD-Storage at the side of wall

BAD Nail coming out & Broken

GOOD-Chemical Storage Practices

Is it right ??????

Kya Yeh Sahi Hai ????

Kya Yeh Sahi Hai ????

Requirement for refuse storage

Lids must be tight and well fitting They must be emptied and cleaned regularly

Insect - o- cutor
Should be always on while work is in progress

Rat Station -Instructions

Rat Trap Keep this ok always

This may lead to pest breading

PERSONAL HYGIENE
Why is Good Hygiene Important to Food Safety? All of us carry disease-causing bacteria on or in our bodies. These bacteria can be carried to food, where they will make a customer or a coworker sick. By staying healthy and keeping clean, you can prevent an outbreak of foodborne illness.

It is all about you!

POOR PERSONAL HYGIENE HABITS OFTEN LEAD TO FOOD SAFETY PROBLEMS

Employees must be trained on personal hygiene habits Written instructions on personal hygiene are required Rules must be : Established, Implemented and Enforced

WASH HANDS

After visiting the w.c. On entering a food room After combing hair After eating, smoking, Blowing nose After handling waste After handling raw food

HAND WASHING PROCEDURE

Wash hands with hot water Use soap and a nail brush Clean nails and between fingers Rinse with water Dry Disinfect (with sanitizer)

THIS PHOTOGRAPH SHOWS MICROBIAL GROWTH ON AGAR 24 HOURS AFTER BEING TOUCHED BY A WORKER WITH DIRTY HANDS.

THIS IS THE RESULT OF WASHING WITH SOAP AND WATER FOR ONLY TWENTY SECONDS.

WASHING WITH SOAP AND WATER FOR AN ADDITIONAL TWENTY SECONDS (40 SECONDS TOTAL) RESULTS IN EVEN MORE BACTERIA BEING REMOVED FROM THE FINGERS.

THIS IS THE RESULT OF WASHING WITH SOAP AND WATER FOR FORTY (40) SECONDS FOLLOWED BY THE USE OF A HAND SANITIZER.HARDLY ANY BACTERIA REMAIN ON THE FINGERS.

HAIR THAT GETS INTO FOOD IS NOT ONLY UNSIGHTLY AND UNAPPETIZING, IT IS LOADED WITH BACTERIA. NOTE THAT EACH STRAND OF HAIR ON THE PLATE IS COVERED WITH BACTERIA.

Jewellery

Traps bacteria Chemical reaction with foods May drop into food

SMOKING

Is illegal in food rooms: 1. Transfer bacteria via saliva

2. Causes coughing 3. Contaminates work surfaces 4. Produces an unpleasant environment

PROTECTIVE CLOTHING MUST BE

Clean Washable Light colored No buttons No pockets

Employee Health
Employees should NEVER work with food if suffering from any of the following conditions: Fever Diarrhea Upset Stomach Sore throat Coughs/colds Dizziness Such Employees must stay at home until well !

SANITATION CONTROL:
Cleaning Equipment Monitoring SSOPs Records to be maintained Personnel practices Equipment practices Plant facilities Warehouse practices Equipment & operation design

SANITARY FACILITIES
Hand washing - soap, sanitizer, procedures, signboards Equipment cleaning area Water quality, treatment, testing, records Storage of product - humidity control, pests

Sanitation Standard Operating Procedures (SSOP)

Safety of water Condition and cleanliness of food-contact surfaces Prevention of cross-contamination Maintenance of hand-washing, hand-sanitizing and toilet facilities

STOP CROSS CONTAMINATION

Keep raw food and cooked food separate Use colored coded boards &knives

To Stop cross contamination

Keep all items separate and covered Use separate stacking boards & place Keep the contact surfaces clean

CONTAMINATION

BACTERIA THE CHAIN OF INFECTION ILLNESS

FOOD

MULTIPLICATION

BREAKING THE FOOD POISONING CHAIN

PROTECT FOOD FROM CONTAMINATION CONTAMINATION

PREVENT MULTIPLICATION

MULTIPLICATION

DESTROY THE BACTERIA BACTERIA

PROTECT FOOD FROM CONTAMINATION

Cover food Avoid handling food Separate raw and cooked food Eliminate animals and insects Practice personal hygiene Careful refuse disposal Keep clean

Sanitation Standard Operating Procedures (SSOP)

Protection from adulterants Labeling, storage and use of toxic compounds Employee health Exclusion of pests

If Sanitation is in Place, it results in developing an Effective HACCP Plan GMP & SSOP are to be effectively controlled. All effort to be made to Focus on hazards associated with Food. Exception: Although CIP (Clean-In-Place) is a sanitation activity, could be taken as CCP Pest Control Programs to be covered by SSOP, and not as CCP or a HACCP Plan.

Prerequisite Programs : Others

Steps or procedures that control the in-plant environmental conditions that provide a foundation for safe food production. Examples include:
Training Recall Programs & Traceability Preventive maintenance Product identification program and coding.

Traceability
Identify a unique batch of
Product Raw material used in production

Then follow
That batch and Each individual unit comprising the batch

Through the
Production And/or distribution process ,to immediate consumer

Traceability
All Food Business should:
Define the scope of their traceability system Document their traceability system Set up mechanisms to periodically review their traceability system Test their traceability system when testing their recall procedures

Traceability
Supplier Traceability Traceability of suppliers and their goods entering a business Process Traceability Traceability of food stuffs through a business Customer Traceability Traceability of Food stuffs to immediate customer

Product recall
Recall is Removal of unsafe food from distribution chain Recall extends to Food sold to consumers Recall involves Communication with consumers A recall should be initiated when a foodstuff is identified as unsafe, is a potential risk to public and has been distributed to the consumer

Product Recall
Object is to
Protect public health by informing consumers of the presence on the market of a potentially hazardous foodstuff And by facilitating the efficient, rapid identification Removal of unsafe foodstuffs from The distribution chain

Thus ensuring that the unsafe foodstuffs are

Either destroyed or Rendered safe

WITHDRAWL
This is removal of an unsafe foodstuff from the distribution chain but dose not extend to food sold to the consumer A withdrawal should be initiated when a food stuff is identified as unsafe, is a potential risk to public health but it can be demonstrated that the unsafe foodstuff remains wholly in the distribution chain and has not reached the consumer

Stages of Product Recall Procedures

Development of a product recall policy Development of a product recall plan Testing of a product recall plan Notification and initiation of a product recall Management of a product recall Closing a product recall Review of a product recall plan Amendment of the product recall plan

Recall plan-role and responsibilities

Recall Coordinator
Distribution Product &QA Consumer affairs Accounting Legal Counsel Public Relations Technical Marketing Regional Sales manager

Owner /CEO
1.Stop all distribution-arrange for return. 2.Prepare inventory and distribution status of product. 1.Preapre batch identification. 2.Halt production of product if related problem. 3.Investigatefor cause of problem ,check all records. 1.Prepare response for consumers. 2.Answer all consumer enquiries. 1.Set up stock reconciliation system to determine cost of recall. 1.Handle legal complications.

1.Handle press releases-All media. 1.Obtain batch identification and samples. 2. Obtain product analysis to determine if pick-up or destruction necessary. 3.Consult with regulatory agencies if a recall is required. 1.Notify sales manager and brokers. 2.Arrange for pick-up at retail levels. 3.Arrange for proper credit to be given. 1.Aid contacting customers. 2.Assist in product pick-up and delivery of credit notes.

Product Recall Decision Tree

Complaint or notification of product problem Report received initial details taken

Notify Quality Assurance Manager or other

QA Manager-Make preliminary risk assessment

No health hazard

Potential health hazard Notify Co. Executives Invoke recall plan Notify Regulatory Authorities Suspend distribution of product

Handle as complaint Or Quality Recall

Convene recall team Collate all product/ prod. Info. Initiate product analysis where necessary Collate all traceability information No health Hazard Handle as complaint or quality recall

Conduct documented through risk assessment

Health Hazard confirmed Product distributed to consumers

Product distributed to consumers via caterers

Product not distributed to consumers

CARRY OUT RECALL

CARRY OUT WITHDRAWL

Sample Trade Notification

URGENT Product Recall (or withdrawal ) Company Name Product Name Product Details ________________________________ ________________________________ ________________________________

Batch Identification ________________________________ Use by' or BB date ________________________________ Reason for the Recall ___________________________________________________ ___________________________________________________ Action Required ___________________________________________________ ___________________________________________________ Contact Details Alternative Contact Details ____________________________________ ___________________________________

Product Recall Notice

WARNING Food Product Recall Company name Product Name /Description Pack Size Batch Identification
Product Photograph or illustration

Details of what is wrong with the product

Action the consumer should take We apologies for any inconvenience Company address and contact details

THE HACCP APPROACH

The Codex Guidelines identify 12 steps for the implementation of the 7 HACCP Principles.

CODEX 12 STEPS
HACCP Implementation as per Codex Guidelines: 12 steps 1. Formation of HACCP Team 2. Product Description 3. Intended Use of the Product and Customer 4. Process Flow Diagram 5. On-Site Verification of the Process Flow 6. Conduct Hazard Analysis and Identify Preventive 7. Identify CCP 8. Set Critical Limits 9. Monitoring of critical limits associated with each CCP 10. Establish Corrective Actions when the CL deviate 11. Establish Verification Procedures 12. Record Keeping Procedures

Developing a HACCP Program

To set up a foundation the following basics are required 5 steps
Assemble HACCP team Describe the product Identify Intended Use Develop a flow diagram On site verification of flow diagram

HACCP TEAM
FUNCTION IN TEAM NAME POSITION WITH COMPANY KNOWLEDGE/ SKILLS and Experience (Years)

Team Leader Team Member Team Member Team Member Specialist Specialist Others

Product Description
Product Name Composition End Product Characteristic Method of Preservation Packaging - Primary Packaging -Shipping Storage conditions Distribution Method Shelf Life Special Labeling Sweetened Carbonated beverage-brand/diet/water Write Ingredients ---------colored/transparent, clear liquid, without suspended matter, sweetened and biting Low pH, Anaerobic condition by Carbonation Glass/ Food Grade Pet bottle with PVC blend crown / pp PVC cap in 200,300,600,2000ml ---- colored plastic crates with ----pockets & printed CFB boxes of ---- ply ,printed/plain Ambient temp, cool and dry place away from direct sunlight By Vehicle ------months from the date of mfd/ pkg. Diet - Contains aspartame, not suitable for phenylketouranics ,not for children below 12 years of age Consume as such preferred serve chilled

Customer Preparation

STEP 3: Intended use

For general people For elderly For infants For immunologicaly challenged allergic
milk, pea nut, tree nut (ex. walnut), sesame, egg, fish, shell fish , wheat, soy

Symptoms of Allergy
Symptoms typically appear within minutes to two hours after a person has eaten the food to which he or she is allergic. Tingling sensation in the mouth Swelling of the tongue and throat Difficulty in breathing Hives Vomiting Abdominal cramps Diarrhea Drop in blood pressure Loss of consciousness, and death.

Step 5 :Example of Basic Flow Diagram Receiving of Green Leaf Trailer Unloading Trough Loading/Spreading Withering Rolling Addition of Media Packing

Conditioning Distribution

STEP 5 : Onsite verification of the flow diagram

A Step Missed Hazards missed Potential safety risk

Seven Principles of HACCP

1. List all potential hazards , Conduct Hazard Analysis, Identify preventive measures. 2. 3. 4. 5. 6. 7. Determine Critical Control Points (CCP) Establish Critical Limits for each CCP Establish a monitoring system for each CCP. Establish corrective Action for deviation that may occur. Establish Verification Procedures. Establish Record-keeping and Documentation.

Principle 1: Conduct Hazard Analysis. Prepare a list of steps in the process where significant hazards occur and describe the preventive measures.

Hazards Limited to food safety HACCP Team will analyze

Each hazard - Risk, Likelihood of occurrence and Severity of hazard to be analyzed. Experience, Technical information. Consider factors beyond immediate control Decide which hazards are significant Safety concerns Vs. Quality concerns

Hazard Analysis:
a. Brainstorming - List of potential hazards at each step (RM to Final) not confined to likelihood of occurrence b. Risk Assessment - Focus on reasonably likely to occur hazards (Health risk to consumers)

Part A.

HAZARD IDENTIFICATION List All Potential Hazards

Sources of Potential Hazards

Raw materials Plant and equipment design Intrinsic factors in the product or raw materials Process design (Procedures) Personnel (Staff / Visitors) Storage and distribution

Examples of raw materials are:

Food ingredients (chilled, frozen, dry, liquid). Water (used in formulation or to wash or rinse products). Cleaning chemicals. Packaging. Pesticides, insecticides

Part B. HAZARD EVALUATION

Conduct Hazard Analysis and Determine the Significance of the identified Hazards
Determine Likelihood of occurrence Determine Severity/ Influence of PrerequisitePrograms Determine Significance Method 1 Method 2

A significant hazard has the potential to cause serious illness or injury when the food-stuff is consumed.

Determine Significance of Hazards - Method 1

In this first method, the likelihood of a hazard ocuring may be simply rated as high (H) or low (L) The severity of a hazard ocurring is also rated as high (H) or low (L) Based on the above, significance of the hazard is then determined

Determine Significance of Hazards Method 2 Matrix Method for Food Safety

Severity (consequences) 1. 2. 3. 4. 5. Fatality Serious Sickness Product Recall Customer Complaint Not Significant Likelihood (frequency) A. Common Repeating B. Known to occur C. Could occur (published) D. Not expected to occur E. Practically impossible

Hazard Significance Matrix for Food Safety

FREQUENCY CONSEQUENCE 1 2 3 4 5 1 3 6 10 15 2 5 9 14 19 4 8 13 18 22 7 12 17 21 24 11 16 20 23 25 A B C D E

L X S = Risk Factor
Likelihood ( L ) Once in 3 years Once in a year Once in 6 months Monthly Weekly Daily Factor 1 2 3 4 5 6 Severity ( S ) Lethal -Death Organ Removal Ill for a month Ill for a week Minor health injury Presence not Preferred Factor 6 5 4 3 2 1

Above 6 RF = Significant Hazard

FOOD SAFETY DESCRIPTORS

CCP: Critical Control Point FOOD SAFETY CP: Control Point

Contorl measure(s) that must be in place to address food safety of significance Conrol measure (s) that are in place to address food safety hazards of lesser significance

HAZARD ANALYSIS WORK SHEET

Hazard Analysis Work Sheet

Product Name: Firm Address: Product Description: Method of storage and Distribution: Intended Use and Customer: (1) Ingredient/ Process Step (2) Identify Potential Hazard, Controlled or enhanced at this step (3) Are any Potential Food Safety Hazard Significant (4) Indicate Likely hood & Severity of Hazard H,M,L (5) Justify your decision for column 3 (6) What preventive measures can be applied to prevent the significant Hazard? (7) Is this step Critical Control Point /CQP Yes / No

Write Process Step No. & Name

Biological Chemical Physical Quality

Part C.
IDENTIFY CONTROL MEASURES

Identify Control Measures

Control Measures are any factors, actions and activities that can be used to control an identified food safety or quality hazard. Control measures must eliminate, control or reduce the effect of a hazard to an acceptable level

CONTROL MEASURES for Biological hazards

Pasteurization - application of time/temperature Fermentation Acidification - pH control Pickling - addition of salt Drying - Aw reduction Freezing/cooling Training to prevent cross contamination

Control Measures for Chemical Hazards

Supplier Quality Assurance Programs Certificate of Analysis - signed and meet specification Sanitation Program - approved food grade chemicals, visual inspections Pest Management Program - approved pesticides Antibiotic Testing Designated with-holding period for crop control chemicals Correct Labels - for products containing allergens

CONTROL MEASURES for Physical Hazards

Sieves - use nitex (not metal wire) Screens Magnets Filters Metal Detectors Glass Control Policy Good Manufacturing Practices - personal hygiene procedures Use of Plastic (not Wooden) Pallets.

FOOD SAFETY HAZARDS ASSOCIATED WITH THE BEVERAGE INDUSTRY

PRINCIPAL RAW MATERIALS/ INGREDIENTS USED FOR MANUFACTURE OF NON ALCOHOLIC SOFT DRINKS. WATER AROMATIC SUBSTANCES SWEETENERS CARBON DIOXIDE ACIDS COLOURING MATTER PRESERVATIVES ANTIOXIDANTS EMULSIFYING/ STABILIZING/ THICKENING AGENTS

WATER
HAZARDS MICROBIOLOGICAL - PATHOGENS, NATURAL SAPROPHYTES, PROTOZOA ETC CHEMICAL- PESTISIDES, HEVAY METALS, OTHER INORGANIC COMPOUNDS PHYSICAL SUSPENDED MUD, ODOUR, ORGANIC MATTER SEVERITY/ LIKELYHOOD COMMONLY OCCURING, CAN CAUSE SERIOUS DAMAGE TO HEALTH PREVENTION TREATMENT OF WATER BY UV, RO, CARBON FILTER ETC PROPER SELECTION OF SOURCE

CAFFEINE
Hazardous when used in overdose with effects like restlessness, nervousness, insomnia, diuresis etc

SYNTHETIC AROMATIC SUBSTANCE

Presence of Heavy Metals , Impurities etc

LIKELYHOOD/ SEVERITY
Medium

PREVENTION
Regulated application, COA from suppliers etc

ACIDS
CITRIC ACID, MALIC ACID, PHOSPHORIC ACID HAZARDS Excess use of Phosphoric Acid causes loss of Calcium from body, Reduces absorption of Mineral. LIKELYHOOD/ SEVERITY Medium PREVENTION Regulated application

PRESERVATIVES
SODIUM BENZOATE, POTASSIUM SORBATE, SULPHUR DIOXIDE HAZARDS Sodium Benzoate dosage above 1.8g/Kg is toxic. LIKELYHOOD/ SEVERITY Medium PREVENTION Regulated Application

SWEETNERS

SUGAR, SACCHARIN, ASPERTAME HAZARDS Pesticides in Sugar, Moisture, Odour in Sugar after Acidification, Over usage of Aspartame causes cellular death of Neurons, toxic for PKU. LIKELYHOOD/ SEVERITY Medium PREVENTION Raw Material (Sugar) inspection and testing, Source Control and monitoring, regulated application of other sweeteners, proper labeling.

EMULSIFIERS, STABILIZERS, THICKENING AGENTS

PECTINS, ALGINATES, CARRAGENEN ,SYNTHETIC MATERIALS HAZARDS Impurities, Character Hazards LIKELYHOOD/ SEVERITY Medium PREVENTION Raw Material Inspection, Testing, COA

CO2

HAZARDS Impurities viz. Sulphur Compounds LIKELYHOOD/ SEVERITY Medium PREVENTION Raw material testing, COA from Supplier

Principle 2: Identification of Critical Control Points

Objective
The definition of Critical Control Point(CCP) The relationship between a significant hazard and a CCP A CCP may change for product formulations and processing lines The use of a decision tree to select a CCP Examples of CCPs.

Definition Critical Control Point:

A point, step or a procedure at which control can be applied and a food-safety hazard can be prevented, eliminated or reduced to acceptable levels.

For Each Hazard

No
Q 1 Is here a significant hazard at this process step ? Not a CCP

Q. 2 Do Preventive Measures exist ? Modify step, process or product

HACCP DECISSION TREE

CCP

Yes

No Is Control at this step necessary for Food Safety

Yes No

Q. 3 Is the step specifically designed to eliminate or reduce the likely occurrence of a hazard to an acceptable level ?

Not a CCP
Thought required about processing, handling etc

Yes

No

Q. 4 Could contamination with identified hazard(s) occur in excess of acceptable level(s) or could they increase to an unacceptable level ? Question forces consideration of growth or contamination

Yes

No

Not a CCP

Focuses team on realistic end use of product

Q. 5 Will a subsequent step eliminate or reduce the likely occurrence of the identified hazard to an acceptable level ?

Yes Not a CCP

No

Highlights importance of labelling cooking & storage

CCP

Definition Control Point

Any point, step or a procedure at which biological, physical or chemical factors can be controlled.

CCPs Vs. Control Points

CCPs are product and Process-Specific

Principle 3 : Establish Critical Limits

Objective:
How to define Critical Limit How to set Critical Limit for a CCP How to find sources of Critical Limit Information How to determine the relationship between Critical Limits and Operating Limits

Definition :
Critical Limit: A criterion that must be met for each preventive measure associated with a CCP. Boundaries to produce safe food.

Examples of Critical Limits:

Hazard Micro risk Due to yeast CCP Pasteurization of Sugar Critical Limit 81+/- 2 c for 15 sec. Contact time 30 minutes

Sulphur & Sulphur Compounds

Receiving Inspection

CO2 99.9% Purity COA -SUPPLIER T. Sulphur < 0.2ppm

Operating Limits:
Criteria that are more stringent than critical limits and that are used by an operator to reduce the risk of deviation.

Process Adjustment :
An action taken by the firm to bring the process back within operating limits.

Principle 4:
Establish CCP monitoring requirements. Establish procedures for using the results of monitoring to adjust the process and maintain control.

Objective:
How monitoring is defined Why monitoring is needed How to design a monitoring system What methods and equipment are used for monitoring critical limits How often monitoring should be performed Who should monitor

Definition Monitor
To conduct a planned sequence of observations or measurements to assess whether a CCP is under control and to to produce an accurate record for future use in verification.

MONITORING
Purpose of Monitoring To track the operation of the process and enable the identification of trends toward a critical limit that may trigger process adjustment. To identify when there is a loss of control ( a deviation occurs at a CCP ), and To provide written documentation of the process control system.

How Critical Limits and Preventive Measures will be Monitored

MONITORING
WHAT: usually a measurement or observation to assess if the CCP is operating within the critical limit HOW: usually physical or chemical measurements(for quantitative critical limits) or observations (for qualitative critical limits). Needs to be real-time and accurate. WHEN (frequency): can be continuous or intermittent WHO: someone trained to perform the specific WHERE: At what stage or step it is to be moniteredmonitoring activity.

Principle 5 : Corrective Actions

Objective
The definition of Corrective Actions Procedure for Corrective Actions Record-keeping requirements for corrective actions

When a deviation from a critical limit occurs, a corrective action must be taken.

Corrective Action :
Procedures to be followed when a deviation or failure to meet a critical limit occurs.

Corrective Action Components :

To correct and eliminate the cause of the deviation and restore process control. To identify the product that was produced during the process deviation and determine its disposition.

Principle 6 : Verification Procedures

Objective :
How to define Verification What functions are part of HACCP Plan verification How to define validation What functions are part of validation

Establish procedures to verify that the HACCP system is working correctly.

Verification
The use of methods, procedures or tests, in addition to those used in monitoring, to determine if the HACCP system is in compliance with the HACCP plan and/ or whether the plan needs modification and revalidation.

Trust What You Verify

Verification provides a level of confidence that the HACCP plan is based on solid scientific principles, is adequate to control the hazards associated with the product and the process, and is being followed.

Verification activities for CCPs

Calibration Calibration record-review Targeted sampling and testing CCP record-review

HACCP SystemVerification Frequency

Annually Occurrence of a system failure,or Significant change in product or process

Audit Verification activities of the HACCP system :

Check the accuracy of the product description and Flow Chart Check that CCPs are monitored as required by the HACCP plan Check that the processes are operating within established critical limits Check that records are completed accurately and at the time intervals required.

Principle 7: Record-Keeping Procedures

Objective :
What kinds of records are needed in a HACCP system When to record monitoring information How computerized records can be used How to conduct a record-review

Establish effective record-keeping procedures that document the HACCP system

Four kinds of records are kept as part of the HACCP system:

1. HACCP plan and support documentation used in developing the plan 2. Records of CCP monitoring 3. Records of corrective action 4. Records of verification activities.

All HACCP monitoring records should be on forms that contain the following information :
Form title Firm name Time and date Product identification (including product type, package size, processing line and product code, where applicable) Actual observation or measurement Critical Limits Operators signature or initials Reviewers signature or initials Date of review.

OTHER AREAS OF CONCERN

Presence of yeast in sugar Pasteurization ,Raw Material Control, Atmosphere , Sanitation control Activated carbon carry over to product RO after carbon filter Caustic carry over to product GMP-pH testing of wash water Glass pieces carry over to product GMP-Glass policy monitoring Inadequate cleaning of bottles SSOP-periodic monitoring Foreign material carry over to product Identification of source High alkalinity of water leads to poor product quality Proper source selection, use of buffers.

THANK YOU
SGS India Pvt. Ltd., SGS House A-77, Road No.16 Wagle Industrial Estate, Thane. 400 604 Suhas.bedekar@sgs.com