Trade Kings SA

Advanced Food Safety

training for Supervisors

2014/01/29

By Gwen Lombard

Food safety management systems

Why
Cadbury apologises for Salmonella outbreak
Poisoned 37 people from Feb to June 2006.
We regret that any people may have been
unwell,the company said in a statement released
to the Foodproductiondaily.com. We have
already announced that we have changed our
testing protocol and implemented new
procedures to reassure consumers that any
product showing any trace of salmonella will be
destroyed regardless of how low the level
2014/01/29

By Gwen Lombard

What happened
In January 2006, the company discovered that waste water from
a plant in Hereforedshire had dripped down into the milk
chocolate crumb, a mix that is blended with other ingredients to
make some of the companys chocolate bars. The pipe was fixed
but despite finding the salmonella pathogen in some of Its
products, the company failed to make a recall at the time.
Cadbury claims in a press release it did not disclose to officials
that its products could be contaminated with Salmonella
montevideo strain as only minutetraces of the bacteria were
found and the company deemed the risk too low.
Poor layout of the factory and inadequate drainage and
disinfection equipment, and not having the EU hygiene rules
Hazard Analysis and Critical Control Point (HACCP) analysis in
palce are the cause of the scandal.
2014/01/29

By Gwen Lombard

Why SUPERVISORS
A food safety supervisor must be reasonably
available at all times; and:
know how to recognize, prevent and alleviate
food safety hazards on the production floor;
have skills and knowledge in matters relating
to food safety relevant to the food sector;
have the authority to supervise and give
directions about matters relating to food
safety to persons who handle food in the food
business.
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By Gwen Lombard

Supervisors
Therefore, SUPERVISORS must be
reliable, trustworthy and responsible.
Theres nothing wrong with being
wrong, handle the wrong correctly!
build relationships with your team.
Need to set goals = measurable
objectives.
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By Gwen Lombard

Measurable objectives

Limits & Time

Production efficiency of 90% per week
Obtain >85% on external retailer audits
No more than 2 customer complaints per
100 000 units sold
Reduce weekly waste to 1.5%
Obtain >90% on quarterly internal audits
FSSC 22 000 Certified by June 2015

2014/01/29

By Gwen Lombard

Food safety
Def. is related to the presence of foodborne hazards in the food at the point of
consumption.
As introduction of these hazards can
occur at any stage of the food chain,
TRADE KINGS SA has a responsibility.
Food safety is controlled through the
combined efforts of all parties
participating in the food chain >
suppliers > manufacturers > transporters
> storage > retailers > consumers
2014/01/29

By Gwen Lombard

Why the need for food safety

Satisfied & loyal customers

Transparency what we do
Increased population, increased demand
Export/trade opportunities
Competitive
Reduced wastage
Legal compliance
Protection, due diligence & CPA
Customer requirements

Tools for achieving food safety implementation of food

safety management systems (FSMS)
2014/01/29

By Gwen Lombard

PRPs & FSMS

Prerequisite programs:
SANS 10049:2012; ISO/TS22002-1 (replaced PAS 220:2008)
Food sector dependent i.e. Soft drinks, dairy, red meat
Food Safety Standards:
HACCP (SANS 10330:2007 = R908)
ISO 22000:2005
FSSC 22 000 = ISO 22000+PAS 220 > GFSI recognized
South African Acts & regulations:
R962 - National Health Act 61 of 2003 - (replaced R918)
Act 54 of 1972 Foodstuffs, Cosmetics & Disinfectant Act
R908 HACCP based system compulsory
Applicable regulations pertaining product & ingredients
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By Gwen Lombard

Audits & Certification

Certification of FSMS is NOT
compulsory, but may be part of
purchasers requirements; export
requirements; competitive advantage.
Organizations get audited against
standards voluntarily, by a
Certification Body, whom is
accredited to audit specific
schemes in order to certify the
organization.
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By Gwen Lombard

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How does it fit in with TRADE

KINGS SA?
Customer requirements as per FSA Audit
implement HACCP, elements of ISO 22000
in order to progress towards a FSSC 22000
approach.
Plan:
Base PRPs on product sector, ensure by-law
regulations are addressed & adhered to.
Conduct & Implement a full HACCP study
Prepared for retailer audits aligned with
GFSI
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By Gwen Lombard

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Questions
Name the 2 National acts applicable to
TRADE KINGS SA?
R962 replaces which regulation and
under which act?
True or false: HACCP is integrated with
ISO 22000 & FSSC 22000
Are TRADE KINGS SA responsible to
manage the food safety hazards
during transportation?
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By Gwen Lombard

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HACCP background scanning

The 4 types of hazards to be managed
in HACCP:
Physical (bolts, jewelry, metal, dust)
Chemical (toxins, pesticides,
aflatoxins, grade)
Biological (pests, insects, Microorganisms)
Allergens (7 recognized in South
Africa, Exports?)
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By Gwen Lombard

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TRADE KINGS SA TEAM

Multidisciplinary??
Appointed & accepted in
writing?
Who responsible for
calling & chairing
meetings?
Meeting minutes records
Do you know your
product? pH, micro, Aw
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By Gwen Lombard

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Draw the flow diagrams

From Receiving of raw materials to
transportation of final products:
(Not equipment, BUT the process!!!)
Lollipops

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By Gwen Lombard

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Hazard analysis
Have you assessed ALL process steps
> manual decanting, mixing &
transfers, rework, trials, cleaning
chemicals, staff health, temporary
staff, imported ingredients, regulatory
requirements?
Did you apply PIGS at each process
step? (Presence, Introduction, Growth,
Survival)
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By Gwen Lombard

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Food safety hazard YES/NO

pH was out of specification on final
lolly mixture
Wheat derived starch used instead
of maize derived starch
Scale used for measuring
preservatives not calibrated
Salt received from China
Tartrazine was not declared on the
lolly label
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By Gwen Lombard

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Acceptable levels
Customer requirements & ISO 22 000
requirements.
Acceptable levels of an identified hazard
in the final product to be known (legal,
customer, product)
Does the control measure prevent,
eliminate or reduce to an acceptable level
& managed with good record keeping i.e.
supplier evaluations, COA verification
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By Gwen Lombard

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Significance of hazards

Probabilit
y

Model on Probability vs. Severity

3

Severi
ty
assessment

Hazards with a
of 4 or less are
effectively controlled through PRPs.
Hazards with an assessment of 6 or above
needs to be taken onto the CCP decision
tree.
2014/01/29

By Gwen Lombard

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PRPs, OPRPs & CCPs

PRP- Basic conditions and activities that are
necessary to maintain a hygiene environment
throughout the food chain, suitable for the production,
handling and provision of safe end products.
OPRP- A PRP, identified by the hazard analysis as
essential in order to control the likelihood of
introducing food safety hazards to and/or the
contamination or proliferation of food safety hazards
in the products or in the processing environment.
CCP- The last step in the process to prevent, eliminate
or reduce a significant hazard to an acceptable level.

2014/01/29

By Gwen Lombard

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PRPs
Based on BSI British Standard Institute
Construction & Layout of buildings
Layout of premises & workspace
Utilities (water, air, gas, energy)
Waste disposal
Equipment
Management of purchased materials
Measures for prevention of cross contamination
Cleaning & Sanitizing
Pest control
Personnel hygiene and employee facilities
Rework
Product Recall procedures
Warehousing
Product information/consumer awareness
Food defense, biovigilence and bioterrorism
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By Gwen Lombard

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Management of PRPs = PDCA Loop

Plan: Establish which
PRP requirements to
be used as guideline

1.
Plan

Do: Implement the

PRPs as per guideline
Check: Verify that the
PRPs implemented
are effective
Act: Corrective
Actions from PRP
audits to be actioned,
closed out and verified
after the audit to
ensure the PDSA loop
is followed through
and therefore ensure
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4.
Act

PRPs

Management

2.
Do

3.
Chec
k

By Gwen Lombard

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Categorization of control measures

Control measures shall be categorized
as to whether they need to be
managed through the PRP, OPRP or
HACCP plan (ISO 22000 requirement)
Inline

Offline

CPs (not addressed in ISO 22000) & CCPs

OPRPs

2014/01/29

By Gwen Lombard

PRPs

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Control measure algorithm CCP vs OPRP

Q1: Do control measures exist that can effectively
eliminate or reduce it to an acceptable level and can they
be monitored?
YE
NO
S measures are there that can be
Q2: How many control
monitored?
1
>
1
Q3: Is on of the control measures more effective?
NO Then choose a control measure located
YE
latest in the process and go to Q4.
S
Q4: Is the control measure
a step in the process (clause
7.6)?
Then Its a
YE
NO Then Its an OPRP
CCP
S
Q5: Is there a combination of control measures that can
be monitored and that when applied simultaneously can
eliminate the hazard or reduce it to an acceptable level?
Then choose all and go to Q4
YE
NO Modify product, process and
for each CM
eliminate through PRPs
S
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By Gwen Lombard

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NEXT.
In order to do a proper investigation of
the products & processes, commitment
from MANAGEMENT is needed
(resources: time, money, training,
suitable equipment, capable staff)
.then a very committed TEAM

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By Gwen Lombard

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