Jeff Chilton, VP Of Consulting Services, Alchemy

Jeff Chilton, VP of Consulting Services, Alchemy

Today’s Speaker Jeff ChiltonVP of Consulting Services2

Agenda Why HACCP? HACCP Fundamentals HACCP Compliance Tips Common HACCP Mistakes Measuring HACCP Effectiveness Sustaining a Successful HACCP Systems HACCP Resources Questions?3

Why HACCP? HACCP is Your process control systemto assure no foodborneillness outbreaks occur fromyour facility Your insurance policy toprotect your business,brand, and consumers HACCP is Necessary to meetregulatory requirements andcustomer/audit expectations Endorsed by CODEX,NACMCF, and GFSI Mandated for USDA for allmeat products & FDAregulatory requirements forJuice and Seafood products4

HACCP Fundamentals5

2 Pillars of HACCP Success1.Management Commitment & Support (Top–2.Down approach)Dedicated resources and budget for employee training andcapital expendituresEffective Prerequisite Programs, Monitoring, and Record-Keeping for:–Calibration–Pest Control–Supplier Approval–Foreign Material Control–Product Labeling–Training–GMP’s–Sanitation–Waste Disposal–Maintenance–Storage/Transport–Water Potability6

5 Preliminary Steps to HACCP1.Assemble the HACCP Team2.Describe the food and it’s distribution3.Describe the intended use and consumers4.Develop the Flow Diagram of the process5.Verify the Flow Diagram of the process7

7 Principles of HACCP1.Conduct a Hazard Analysis2.Determine the Critical Control Points (CCP’s)3.Establish Critical Limits4.Establish Monitoring Procedures5.Establish Corrective Actions6.Establish Verification Procedures7.Establish Record-keeping Procedures8

HACCP Compliance Tips9

Monitoring Understand why you are monitoring Identify the best monitoring procedure and determine frequency Clearly identify employees that will perform monitoring Train the employees on testing procedures, critical limits, how to recordresults, and corrective actions Review how to record the information to assure records are complete,accurate and timely Sign-off on records10

Corrective Action (FSIS Regulation 9 CFR 417.3)Records MUST document: The cause of the deviation is identified and eliminated The CCP will be under control after the corrective action is taken Measures to prevent recurrence are established No product that is injurious to health or otherwise adulterated as a resultof the deviation enters commerce11

Types of Verification – Know the Difference! 3 Types of CCP Verification are required by 9 CFR 417.41. Direct Observation of Monitoring2. Record Review3. Calibration of Monitoring Instruments Verification of the overall HACCP System, at least annually Validation of critical limits, critical operational parameters, and HACCP System Regulatory verification12

Record Keeping It is imperative that HACCP records are complete, accurate and timely!– Correct dates– Actual times are recorded– There are no missed monitoring checks– Critical limits are achieved– Records are reviewed Count on HACCP records to prove your products are safe HACCP records demonstrate compliance to regulations Remember, HACCP Records are legal documents13

Common HACCP Mistakes14

Common HACCP Mistakes Not including all process steps in flow charts, including rework, returnedproduct, water, air & gasses Hazard Analysis Worksheet steps and flow chart steps not matching Not identifying or specifying the correct biological, physical, or chemicalhazards specific to the type of pathogens or foreign materials of concern Too many or too few Critical Control Points (CCP’s) identified15

Common HACCP Mistakes Not fully defining CCP Procedures in HACCP plansummaries Insufficient records - not complete, accurate, ortimely Not completing your HACCP plan reassessmentswhen necessary Insufficient HACCP plan validation scientific data orvalidation reports16

Measuring HACCP Effectiveness17

HACCP Metrics Overview Suppliers should set objectives for their food safety and quality systemswith measurable metrics and specific goals Objectives should be routinely measured against goals to assess theperformance of the food safety and quality systems– Recommended monthly or quarterly, but no less than annually Results and trends should be analyzed to identify continuous improvementopportunities for the food safety and quality management system18

HACCP Metrics Recalls – zero tolerance goal! Audit results – passing within top two scoring tiers External and internal audit non-conformances identified – quantity and trends Customer Complaints – based on % targeted improvement over baseline results Non-Conforming Product - # incidents and based on % targeted improvement overbaseline results CCP Deviation History - # of deviations19

HACCP Metrics USDA NR’s Non-Compliance Records – quantity and % targeted improvement overbaseline results Vendor Non-Conformances - # of incidents, trend analysis and % targeted improvementover baseline results SSOP Results – number of pre-operational and operational sanitation deficiencies, basedon % targeted improvement over baseline results Microbiological Results – finished product testing % compliance within specification;food contact surface and environmental testing & compliance with goals Corrective Action Results - # incidents and effectiveness evaluation to prevent recurringdeficiencies20

Food Safety & Quality System Automation QA departments manage huge volumes of information related to supply chainmanagement, written programs, records, and microbiological results Paper records can be replaced with electronic records It is highly recommended that you electronically automate food safety andquality systems with software that manages the processes, such as SafetyChain, Safe Food 360, TraceGains and Intelex Trend analysis of results can be completed to drive continuous improvement21

Sustaining a Successful HACCP System22

HACCP Reassessment Overview – When To PerformAnnuallySignificantchange madeReassessmentsAware of newinformationUnforeseen foodsafety issueCCP failures Perform before a change isoperative and within 90 days of anew plan Revise the HACCP Plan if asignificant change is made ordocument basis for no revision Performed by a HACCP trainedindividual USDA or FDA determines if it isnecessary to respond to newhazards or developments23

Annual HACCP Reassessments Should Assess: Written HACCP Plan Microbiological Results HACCP Records Annual HACCP Plan ReassessmentChecklist SSOP and SSOP Records CCP Verification Audits Pre-op and OperationalSanitation Audits Reassessment Report and ValidationReference Report HACCP Plan ReassessmentValidation Worksheet Prerequisite Programs24

HACCP Reassessments Do– Review the written HACCPplan and SSOP– Review 60 days of HACCPrecords SSOP and SSOP Records CCP Verification Audits Pre-op and OperationalSanitation Audits Prerequisite Programs Microbiological results Don’t– Just changed the date on acover page and re-sign it– Forget to verify the flowchart25

Ongoing HACCP Team Meetings Regularly Scheduled Meetings Minimum annually butrecommended quarterly Review HACCPperformance Discuss trends in deviations Discuss changes needed For Cause Meetings Specific Meetings Address changes to theHACCP system Address HACCP Deviations Recommended to rotateHACCP Team Members tokeep it fresh and involvemore people for sponsorship26

Additional HACCP Sustainment Activities Train new HACCP Team Members Refresh HACCP Training periodically Stay current on regulatory updates through free USDA and FDA web sitessubscriptions Stay current on new scientific information through industry news, tradeassociations, trade magazines and other sources Evaluate new technologies available to increase product safety such asantimicrobial interventions, antimicrobial ingredients and post lethalityprocesses27

HACCP Resources28

Alchemy’s Employee Engagement Solutions Train your employees with multilingual HACCP courses Reinforce HACCP fundamentals with huddle guides and signage Use reinforcement elements to drive continuous improvement with an on-the-job coaching app Compliance! Stay audit-ready with automatic documentation and real-time reporting29

Alchemy’s Consulting Solutions New HACCP Plan Development – Developed customized HACCP Plan(s) to meetregulatory requirements HACCP Plan Reassessment – Receive a detailed review of your HACCP system toverify accuracy and effectiveness HACCP Plan Validation – Receive scientific and/or in-plant data to verify theeffectiveness of your HACCP Plan Basic & Advances HACCP Training – On-site30

Get Accredited Online HACCP TrainingBasic HACCP Basic HACCP Juice & Beverage Advanced HACCP Accredited by the International HACCP Alliance Receive a certificate of completion Teaches you how to develop & implement an effective food safety plan based onCODEX HACCP specifications, which is required by the four major GFSI schemes– SQF, BRC, FSSC 22000, and IFSLearn more at: y/coursesexams/haccp/

THANK YOUJeff Chiltonjeff.chilton@alchemysystems.comSchedule a Free 30-minute consultationTelephone Andy Chilton: 706.483.4400or email at solutions/professional-services

Basic HACCP Basic HACCP Juice & Beverage Advanced HACCP Accredited by the International HACCP Alliance Receive a certificate of completion Teaches you how to develop & implement an effective food safety plan based on CODEX HACCP specifications, which is required by th