FOOD SAFETY MANAGEMENT SYSTEM

BASED ON FSSC 22000:2013

02 Days Training- 08th & 09th April, 2016

TUTOR’S PROFILE

 Shaharyar Ahmed
 Masters in Food Science & Technology
 Lead Auditor for ISO 22000:2005/ FSSC 22000, ISO9001:2008, HACCP, Halal,
IFS and conducted 1000+ audits
 Supplier Audits like SQA, SQE and MAS
 Auditor for BRC
 Auditing experience : Catering, Dairy, Juice, Ready to eat Packed Foods,
Spices, Cereals, Confectionery, Fruits and Vegetables, Packaging Firms,
Edible Oil, Fisheries Pharmaceutical sector, Textile sector, Hospital, Education
Sectors
 Experience of 07 years in Processing, Quality Assurance, GMP compliance,
Trainings & Development and Consultancy projects.
 Author of a Book “ Modern Day Industrial Application of Food Safety”

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DELEGATES INTRODUCTION

 Please introduce yourself

 Your Full name.
 A brief Job description.
 Your Awareness regarding Food Safety Standards e.g.
ISO 22000:2005, HACCP, BRC or any other food
Standard
 Your Objectives of participation

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 SESSION NORMS

 House Information & rules :

 Timings & attendance

 No-smoking area
 Lunch & Tea Break
 Washrooms
 Courtesy-Mobile phones etc.

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BASIC QUESTIONS

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 What is Food Safety ?

ALL steps in food production taken to ENSURE that food is SAFE, WHOLESOME an
FIT for HUMAN CONSUMPTION.

We ensure Good Food Hygiene by:

PROTECT - Protect food from contamination at EVERY PROCESS STEP,
PREVENT - Prevent any bacteria present FROM MULTIPLYING to dangerous
levels,
DESTROY - Destroy any bacteria present by PROPER COOKING and
PROCESSING.

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 Food Contamination

PHYSICAL BACTERIAL CHEMICAL

 Examples :  Examples :
 Examples :
 Dead Insects  Detergent,
(sometimes live)  Salmonella,
 Paper & Cardboard  Clostridia,  Aflatoxin B1,
 Plastic, Metal, Plasters,  Listeria,  Oil leakage from
 Cleaning Materials, processing
String,  Staphylococcus,
Equipments
 Rodent hair &  Bacillus,
droppings,
 Sweet Papers, Pen
Tops, Grease,
 Glass, Cigarette Ends,
and so on...

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 Why do we need Safe Food
Standards ?
The COSTS of Poor Hygiene
 Food Poisoning Outbreaks &
Sometimes Death
 Customer Complaints
 Pest Infestation
 Wasted food (spoilage)
 Closure of premises (loss of
jobs)
 Fines and costs of legal actions
 Civil action taken by food
poisoning victims
 Loss of Profit
The BENEFITS of Good Hygiene
 One Satisfied Customer Leads
to Another
 A Good Reputation
 Increased Business
 Compliance with the Law
 Longer Food shelf Life
 Better Working environment
 Higher Staff Morale
 Increased Profits
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 FOOD SAFETY STANDARDS
APPLICABLE AT:

 Feed Producer - Cleaning agent

 Primary producer - Packing material
 Food manufacturer - Additive and ingredient
 Transportation - Services providers
 Storage operation - Producer of equipment
 Food services outlet

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Food Safety Standards

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 Neglected Fields by the Food
Professionals

 Certification Bodies
 Consultancy Firms
 Industries

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 Neglected Fields by the Food
Professionals

 Certification Bodies
 Consultancy Firms
 Industries

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Leading Fast Food brands
- Food Qualified Working

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Restaurants Food Qualified
01

02

01

--

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Restaurants Food Qualified
10

01

01

00

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Leading Packaged Food
brands- Food Safety Certified

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Leading Hotels- Food Qualified
Working

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All these organizations are
HACCP Compliant or Certified.

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HISTORY OF ISO AND ISO 22000

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 PDCA CYCLE
Establish objectives
Take actions to continually necessary to deliver
improve process performance – results in accordance
effectiveness and efficiency with customer
Act Plan requirements
• What to do
• How to improve • How to do it
and the organisation's
next time? policies

Check Do
• Do what was
• Did things happen planned
according to plan?
Monitor and measure Implement the
processes and product processes
against policies, objectives
and requirements

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 ISO 22000 PILLARS

Interactive System
communication management

Prerequisite HACCP principles

programmes

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 THE STRUCTURE OF ISO 22000

ISO 22000
Food safety management systems – Requirements for any
organization in the food chain

 1 Scope
 2 Normative references
 3 Term and definitions
 4 Food safety management system
 4.1 General requirements
 4.2 Documentation requirements

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 THE STRUCTURE OF ISO 22000

 5 Management responsibility
 5.1 Management commitment
 5.2 Food Safety policy
 5.3 Food safety management system planning
 5.4 Responsibility and authority
 5.5 Food safety team leader
 5.6 Communication
 5.7 Emergency preparedness and response
 5.8 Management review
 6 Resource management
 6.1 Provision of resources
 6.2 Human resources
 6.3 Infrastructure
 6.4 Work environment

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 THE STRUCTURE OF ISO 22000

 7 Planning and realization of safe products

 7.1 General
 7.2 Prerequisite programmes
 7.3 Preliminary steps to enable hazard analysis
 7.4 Hazard analysis
 7.5 Establishing the operational prerequisite programmes
 7.6 Establishing the HACCP plan
 7.7 Updating of preliminary information and documents
specifying the prerequisite programmes and the
HACCP plan
 7.8 Verification planning
 7.9 Traceability system
 7.10 Control of nonconformity

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 THE STRUCTURE OF ISO 22000

 8 Validation, verification and improvement of the FSMS

 8.1 General
 8.2 Validation of control measure combinations
 8.3 Control of monitoring and measuring
 8.4 Food safety management system verification
 8.5 Improvement

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HISTORY & BACK
GROUND

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HACCP

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 WHAT IS HACCP

HACCP is a preventive approach to food safety

Programs are designed, operated, monitored and verified to

prevent human health hazards.

 Is not a guarantee of food safety and is not a zero-risk system.

It is designed to minimize the risk of food safety hazards

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 ADVANTAGES OF HACCP

 Improves control of food processes

 Controls Food cost
 Reduces Food Waste
 Provides Continuous Self Inspection & Improvement
 Helps with complaints and legal actions
 Complies with Law
 Protects customers
 Organizational Image

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 HACCP Principles
HACCP is a systematic approach to the identification, evaluation, and
control of food safety. HACCP based on the following seven
principles:

Principle 1
Identify the potential hazards associated with food production at all
stages, from growth, processing, manufacture and distribution to the
point of consumption. Assess the likelihood of occurrence of the
hazards (risk assessment) and identify preventive measures for their
control (risk management).
 Biological
 Chemical
 Physical

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 HACCP Principles
Principle 2
Determine the points, procedures, and operational steps that can be
controlled to eliminate the hazards or minimize their likelihood of
occurrence; these are the critical control points (CCPs). A "step"
means any stage in food production and/or manufacture including
receipt and/or production of raw materials, harvesting, transport,
formulation, processing, storage, etc.

Principle 3
Establish critical limits, which must be met to ensure that the CCPs
are under control.

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 HACCP Principles
Principle 4
Establish a system to monitor control of CCPs by scheduled testing or
observations.
Principle 5
Establish the corrective action to be taken, when monitoring indicates
that a particular CCP is not under control.
Principle 6
Establish procedures for verification, which include supplementary
tests and procedures to confirm that the HACCP system is working
effectively.
Principle 7
Establish documentation concerning all procedures and records
appropriate to these principles and their application.

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PROPER CONSTRUCTION AND LAY OUT OF
BUILDINGS:

 It talks about proper designing, construction and

maintenance of building. Building should be present in
such a condition that poses no risk to the production of
safe food. It also includes proper preventive measures to
prevent the access of pollution from external environment.

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LAY-OUT OF PREMISES AND SUPPLIES OF AIR,
WATER AND ENERGY:

 It includes the appropriate movement flow of man,

material, product that prevent cross-contamination of the
product. It also includes proper internal design, structures
and fittings.

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WASTE AND SEWAGE DISPOSAL:

 Organization has to ensure that waste materials are identifi

ed, collected, removed and disposed off in a proper manne
r. All trash cans should be identified and made up of imper
vious material that can be easily cleaned. Trash cans shou
ld be closed when not in immediate use. Proper frequency
and procedure needs to be established for timely dispositio
n of wastage. It also includes proper designing and constru
ction of drains.

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SUITABILITY OF EQUIPMENT

 All equipments that come in direct contact with food should

have hygienic design. It means that equipments should be
smooth, easily accessible and cleanable surfaces. Organi
zation has to establish and put in place corrective and prev
entive maintenance of all equipments that have impact on f
ood safety.

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CLEANING AND SANITIZING:

 Organization has to establish cleaning and sanitizing proce

dures that ensure that food-processing equipments and en
vironment are maintained in a hygienic condition.

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MANAGEMENT OF PURCHASED MATERIAL:

 Supplier Evaluation
 Supplier Selection
 Supplier Monitoring
 Supplier Re-Evaluation

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MEASURES FOR THE PREVENTION OF CROSS
CONTAMINATION:

 Organizations have to take all the measures that prevent

product from cross contamination. Product can be
contaminated through physical, chemical and microbial
contamination. These contaminations can be controlled by
taking measures like separation of raw, semi-finished and
finished products; provision of physical barriers between
different product categories; and having apt system to
control and manage man, machine and material flow.

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PEST CONTROL:

 To get pest-free production environment, organization

needs to maintain a good building structure. Appropriate
measures have to be taken for all the access points of
pests e.g. doors, windows, ventilations, drains, holes.
Monitoring is required to identify pest activity and for that
purpose, regular monitoring of pest catcher equipments
like insectocutors and traps need to be conducted. When
pest activity/ infestation is reported, eradication activity has
to be carried out without delay.

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PERSONNEL HYGIENE:

 To comply with personnel hygiene requirements, organizations should

have sufficient hand washing, sanitizing and dryer facilities at appropriate
locations; and adequate number of toilets, changing rooms, lockers, staff
canteen/designated eating-area. Procedure should be in place for staff
workwear (uniforms) and protective clothing. Based on risk, regular
medical screening record of production staff should be carried out to pick
any contagious disease in an employee. It is mandatory for the
organization to screen the employees for any disease that can
advertently or inadvertently compromise food safety. Procedure should
be available to detail actions that need to be taken in cases of staff illness
and injury. Proper measures have to be implemented in case a person
gets ill or is injured to prevent product from cross-contamination.
Organization has to establish and implement proper policy for jewellery
control, perfume control, and eating control in work area amongst other
things.

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