HACCP MANUAL
HAWAII INTERNATIONAL SEAFOOD, INC . Frozen Seafood ProductsHACCP MANUALHygiene, Sanitation Standard OperatingProcedure and HACCP for suppliersSummer 1999
Prepared For:Cryofresh manufacturing facilities are audited by the NationalMarine Fisheries Services (NMFS), Seafood Inspection Program,to verify compliance with the following applicable standards: USFDA HACCP EU (European Union) TSSA Tasteless Smoked Seafood AssociationCopyright October 1999Contents from this document may not be reproduced in whole or in part without the expressed writtenconsent of Hawaii International Seafood, Inc.Page I
HACCP MANUALI. Table of ContentsPage 1. Table of ContentsPage 2. IntroductionPage 2. Personal HygienePage 2. Photo # 1. Workers Using Masks and Gloves.Page 3. Example IIIA: Personnel Hygiene CodePage 3. Sanitation Standard Operating ProcedurePage 4. Photos # 2 and # 3. Ice Potability and Thermometer ChecksPage 7. Cleaning SchedulePage 7. HACCP PlanPage 8. Photo #5 and #6 Packaging Material HandlingPage 9. Example: SSOP plan.Page 11. Example: Calibration ChecklistPage 12. Example: Chlorine Checklist and Glass ChecklistPage 13. Cleaning SchedulePage 13. Example: Map, Facility Areas of ResponsibilityPage 14. Example: Cleaning InstructionsPage 32. Example: Cleaning Schedule Check ListPage 37. Example: Hazard Analysis WorksheetPage 40. Typical HACCP Plan and RecordsHawaii International Seafood, Inc. is a Charter Member and CertifiedManufacturers Member of the Tasteless Smoked Seafood Association(TSSA). The TSSA establishes strict standards and auditing proceduresto “CERTIFY” products manufactured with “tasteless smoke” and toverify complaince of tasteless smoked products with USFDA food safetyand labeling requirements.Page 1
HACCP MANUALHACCP MANUALII. IntroductionIII. Personal HygieneThe people at Hawaii International Seafood Inc. (referredto in this Manual as H.I.S.) are dedicated to providingconsistently high quality and safe seafood products. Forthis reason we have written this manual as a guide forour international suppliers. We are dedicated to workingclosely with our suppliers to achieve our goal of exceeding international standards for hygiene, sanitation andhazard control in each facility that produces seafood products for H.I.S. This manual is also available on requestfrom H.I.S. on diskette formatted to MS Word for Windows 95, 98 or 2000.All H.I.S. suppliers shall adopt and maintain a Personnel Hygiene Code and training program at each site whereH.I.S. products are produced. In-house training on thePersonnel Hygiene Code for all staff shall be conductedby qualified management personnel at least annually andindividually each time a new staff member is acquired.This manual clearly explains the requirements all suppliers must meet and includes actual examples of thedocuments and records currently in use by our U.S.D.C.and U.S.F.D.A. inspected facilities worldwide.We require that all suppliers meet the minimum requirements as stated in this manual. For this purpose, the word“shall” is used to indicate mandatory requirements andthe word “should” is used to indicate suggestions fromH.I.S.In addition to the requirements set forth in this manualall suppliers shall: Meet or exceed all local Federal, Provincial and /orState health and safety codes for the jurisdiction wheretheir facility is physically located. Be fully aware of and abide by Good ManufacturingPractice for all production operations.Personnel Hygiene Code training shall consist of thorough and complete orientation and explanation of thePersonnel Hygiene Code to all staff members. This training shall be documented for each staff member by theissuance by the supplier of an in-house Certificate ofCompletion for training on the Personnel Hygiene Codefor each individual staff member. This Certificate ofCompletion should be issued only after the individualstaff member has passed an oral or written test on thePersonnel Hygiene Code.The Personnel Hygiene Code example that follows thispage represents the minimum standards required of allsuppliers of seafood products for H.I.S. See exampleIII-A on following page.Note on Surgical Masks and Gloves: Surgical masksand gloves, although not required by H.I.S., may be usedat the option of the supplier. If they are used they shallbe 100% disposable and disposed of each time the individual staff member exits the processing room in whichthey are used. In addition, gloved hands shall be washedas required in the Personnel Hygiene Code prior to putting on gloves and again after the gloves are on. Never under any circumstances export any product produced outside of the guidelines contained in this Manualto H.I.S. without full notice in writing to H.I.S. and theexpress written permission of H.I.S. Produce product only with full regard to environmental, ethical and occupational safety concerns. Be prepared and available for unannounced auditvisits by authorized H.I.S. representatives. Including,but not limited to, maintaining copies of all requireddocuments and records in readily accessible form atthe actual plant site or sites where H.I.S. products areproduced. Maintain at least one copy of this manual, in goodcondition, at the actual plant site or sites where H.I.S.products are produced.PHOTO #1. Workers using masks and gloves. Proper protectiveclothing shall be worn by all personnel in the processing area.Disposable surgical masks and gloves may be used at the option ofthe supplier, but must be used properly.Page 2
EXAMPLE III-A Personal Hygiene CodeHACCP MANUAL1. All personnel entering the receiving or processingareas shall wear the approved protective uniform.IV. Sanitation Standard OperatingProcedureThe processing area uniform shall consist of rubberboots, white smock and white hair-net cap, whitehair net beard snood and mustache snood if applicable.2. Protective clothing shall be worn only immediatelyprior to entering or while working in the areadesignated for its use.Protective clothing shall not be worn outside thearea designated for its use, especially in the eating/smoking area, outside the facility or in the bathrooms.Protective clothing shall be turned in at the end ofeach work shift for in-house laundering.Protective rubber boots shall not be worn outsidethe facility.Each H.I.S. supplier shall write and maintain a plan forSanitation for each facility that produces seafood products for H.I.S. As required by both U.S.F.D.A. and theE.E.C. this plan shall be titled “Sanitation Standard Operating Procedure” (SSOP).The SSOP, at a minimum, shall cover the following sanitation concerns: Pest Control Facility Structure and Layout Facility Maintenance Cleaning and Sanitizing of All Processing Areas andEquipment Personnel Hygiene3. Personnel hair and facial hair shall be fully enclosed within the hair-net cap or facial hair snoodwhile in the processing area. Toilet Facilities4. No jewelry shall be worn in the processing area. Chemicals (Including Chlorine Levels in SanitizingSolutions) Potable Water and Ice Supply5. No perfume or body scent shall be worn by processing personnel. Ventilation6. Fingernails shall be kept short, neat and clean. Waste Disposal7. All wounds cuts, sores, infections or abrasionsshall be reported to the office and covered withdisposable sanitary bandage material. Measuring Equipment Calibration8. All personnel must thoroughly wash their handsand rinse them with chlorine dip (water chlorinatedto 50 PPM) or other H.I.S.-approved sanitizer eachtime they enter a food-contact area.These concerns shall be addressed in detail in writing inwritten form in the SSOP and checked daily using anSSOP Checklist that covers these concerns as written inthe SSOP. This SSOP and SSOP Checklist shall be verified and audited by an authorized H.I.S. technician. Awritten copy of the SSOP and all related records shall bekept in readily accessible form at the actual plant site orsites where H.I.S. products are produced.9. Smoking and eating shall only be allowed in thedesignated rest area.10. Any personnel suffering from infectious disease,including flu, stomach complaints or food poisoning shall report to the office for evaluation prior toreturning to work11. No glass in food-contact areas. Glass StatusPlease see examples IV-A and IV-B on the pages following Photographs 2 and 3. This is an actual SSOP andSSOP Checklist currently in use in a USFDA and USDCinspected facility that supplies both fresh and frozen products to H.I.S.Page 3
EXAMPLE IV-A Sanitation StandardOperating Procedure1. Sanitation Concern: Pests1.1 Eliminate harborage and attractantareas for pests. Method: Designated management and/or processingpersonnel shall keep weeds cut, pick up litter onfacility grounds and keep area clean and free ofharborage areas for pests. Method: Designated management and/or processingpersonnel shall conduct daily survey of facility anddispose of any unused/discarded equipment andmaterials that may become harborage areas for pests. Method: Designated management and/or processingpersonnel shall eliminate standing pools of water onfacility grounds through drainage or manually on adaily basis as allowed by weather. The above methods shall be listed on the SanitationChecklist and checked daily for satisfactory statusby the designated management and/or processingpersonnel.PHOTO # 3. Sanitation standards must be maintained throughouteach step of production, from harvest vessel to final packing andcold storage. Method: All non-product-contact areas and surfacesshall be treated with a non-persistent insecticideweekly to eliminate insect pests. All product-contactequipment and surfaces shall be covered or isolatedduring insecticide application. Alternatively, thisshall be contracted to a licensed pest control company. The above methods shall be listed on the SanitationChecklist and checked daily for satisfactory status bydesignated management and/or processing personnel.1.2 Extermination of Pests Method: An insect electrocution device shall beinstalled at the entrance of the processing plantwithin the first entry door and shall be properlymaintained. Method: Traps or poison bait shall be set out andchecked on a daily basis by designated managementand/or processing personnel or as needed and recommended by a licensed pest control company to helpcontrol rodents.2. Sanitation Concern: Structure and Layout ofProcessing Plant2.1 Plant shall be in such a condition so as toprevent filth contamination from entering plant.(i.e. tracked in mud, airborne dust etc.) Method: Management shall ensure that the processing plant is cleaned and sanitized on a twice-dailybasis by designated management and/or processingpersonnel. The above methods shall be listed on the SanitationChecklist and shall be checked daily for satisfactorystatus by designated management and/or processingpersonnel.PHOTO #2. All water andice used throughout eachphase of product handlingshall meet World HealthOrganization Standards forPotable Water.2.2 The design, layout and materials used in theprocessing plant and employee rest rooms shall beable to be readily cleaned and sanitizedto preclude contamination. Method: Rooms shall be laid out and processingfurniture placed so that they can be readily cleanedand sanitized at least twice daily.Page 4
Method: Walls and floors shall be waterproofed andwashable so as to be easily cleaned and sanitizeddaily. The above methods shall be listed on the SanitationChecklist and checked daily for satisfactory status bydesignated management and/or processing personnel.2.3 Equipment and utensils shall be designed andlocated in such a way as to facilitate daily cleaningand sanitation by designated management and/orprocessing personnel.3 Maintenance. The general condition of thefacility shall be maintained to prevent the introduction of hazards. Method: The general condition of the facility shallbe checked on a weekly basis by the plant manageror the designated assistant manager, who will checkfor such things as peeling paint, roof leaks, loosewiring, unsecured wall panels and the like. Repairsand upkeep shall be ongoing and of a preventativenature. Method: Lights shall be covered to prevent physicalcontamination of the product. Method: Equipment shall be maintained and kept ingood working order. Scales shall be checked againsttested weights and thermometers against 0( ice waterdaily. Cooler refrigerators shall be monitored forproper cooling temperatures. Method: All crew members shall hose down theequipment walls, floors and product contact surfacesof the processing area with clean water every day toremove loose debris. A foaming detergent agent shallbe used in conjunction with the wash down procedure. All floors, walls, sinks, drains and tables shall berinsed with water chlorinated to 50 ppm. Thiswater shall be left on all surfaces for 30 minutesprior to being rinsed off with clean water. Method: Walls, floors and equipment shall bethoroughly rinsed with clean water after 30 minutesoaking process in order to rinse off all chemicals, toprevent chemical contamination of the product bycleaning agents and to sanitize all surfaces. Method: Refrigerated storage areas shall be cleanedand sanitized every month in the manner describedabove, or more frequently as required. Method; All other areas of the facility shall beregularly cleaned and kept free of litter and excessclutter by designated management and/or processingpersonnel. The above methods shall be listed on the SanitationChecklist and checked daily for satisfactory statusby designated management and/or processingpersonnel. All requirements for chlorine levels shall be checkeddaily and results entered on the Chlorine LevelChecklist. The above methods shall be listed on the SanitationChecklist or the Calibration Checklist andchecked for satisfactory status on a daily basis bydesignated management and/or processing personnel.4.2 Chemical Contamination Prevention3.1 Sufficient lighting shall be provided to ensureproduct safety and integrity.5. Sanitation Concern: Personal Hygiene3.2 Equipment and utensils shall be maintainedproperly and kept in good repair.5.1 All employees shall maintain a high degree ofpersonal cleanliness to prevent contamination offood product.3.3 Product contact surfaces shall be kept in goodrepair, and shall be constructed of stainless steel orother non-porous, non-rusting material.4. Sanitation Concern: Cleaning and Sanitizing4.1 The facility and equipment shall be cleaned and Method: All chemicals shall be properly labeled andstored in the Chemical storage area and checkeddaily on the Sanitation Checklist. Method: Employees shall thoroughly wash theirhands with detergent soap and chlorinated waterprior to working in production, after each break andafter using toilet facilities. Hand washing stationsmust be maintained in good working order with soapand clean paper towels in both the toilet and processing areas. Signs shall be posted in the toilet andPage 5
processing areas reminding employees of handwashing requirements. Method: Employees shall remove insecure jewelryprior to fish handling. Clean clothing and waterproofboots will be worn. Method: Eating, drinking, spitting and smoking shallnot be allowed in the processing area or any otherarea where processing equipment or materials arehandled. Method: Employees with illness or injuries that mayreasonably be a possible source of contamination tothe product shall not enter the processing area. Illnessand injury must be reported to management. The above methods shall be listed on the SanitationChecklist and checked daily for satisfactory status bydesignated management and/or processing personnel.6. Sanitation Concern: Rest rooms6.1 Operable, in good repair and convenientlyaccessible toilet facilities shall be maintained andchecked daily by maintenance personnel. Method: Rest room supplies, toilet paper, liquid soap,paper towels etc. shall be supplied and maintainedsufficient to meet employees needs. The above methods shall be listed on the SanitationChecklist and checked daily for satisfactory status bydesignated management and/or processing personnel.7. Sanitation Concern: Water Supply7.1 Water supply must meet local and W.H.O.standards for potable water. Sewage system must bein good working order. The water should be chlorinated to .5-1.5 PPM. Method: Water supply shall be tested every sixmonths to comply with W.H.O.standards for potablewater. The test results shall be kept on file by management. Chlorine level shall be checked daily and entered inthe Chlorine Level Checklist. Method: Sewage backflow and siphonage shall beeliminated and prevented by eliminating crossconnections and placing anti-backflow deviceswherever backflow or siphonage may occur. Thisshall be checked daily on the Sanitation Checklist bydesignated management and/or processing personnel.8. Sanitation Concern: Ice8.1 Ice supply must meet local and W.H.O. standards for potable water. Method: Ice shall be purchased only from the government certified pure ice factory. Ice shall be tested tocomply with local and W.H.O. standards every 6months or certified test copies shall be tendered byice factory. Copies of test results will be kept on fileby management. Water used to make ice shall bechlorinated to 25 PPM and checked daily on theChlorine Level Checklist.9. Sanitation Concern: Chemicals9.1 All chemicals shall be used according tomanufacturer’s instructions and recommendationsand stored in an area with limited access and awayfrom product processing.10. Sanitation Concern: Ventilation10.1 Adequate ventilation and air exchange shall beprovided throughout the facility.11. Sanitation Concern: Waste Disposal11.1 Sewage systems shall be draining properly andconnected to the approved local government sewage system. Processing wastes must be stored anddisposed of properly. Method: Method: Processing wastes shall be placedin proper, sealable and readily sanitized containersand removed frequently, at least once a day. Thisshall be monitored daily by designated managementand/or processing personnel and checked on theSanitation Checklist.12. Sanitation Concern: Packaging Material Storage12.1 All food-contact packaging shall be stored so asto be completely sealed in the manufacturer’soriginal carton. These cartons shall be stored onpallets and covered in clean plastic wrapping. Anyopen food-contact packaging material shall bestored in seal-able sanitized plastic food containers.The packaging storage area shall conform to thesame standards as any high-risk food processingarea.13. Sanitation Concern: Glass ContaminationPage 6
13.1 All glass windows in processing and foodcontact product storage areas shall be checkeddaily for damage. This checking procedureshall be recorded on the Glass Checklist.14. Sanitation Concern: Equipment Calibration14.1 All equipment used for measuring temperature and weight shall be checked daily foraccuracy.14.2 All check weights and counter weightsshall be checked and calibrated by the authorized government authority at least annually.Complete and effective cleaning shall be checked bymanagement at least daily using a Cleaning ScheduleChecklist.A written copy of the current Cleaning Schedule,including the Facility Areas of Responsibility, theCleaning Instructions and the completed CleaningSchedule Checklists shall be kept in readily accessibleform at the actual facility or facilities where H.I.S.products are produced.The hand soap, foaming detergent and chlorine powderor solution used in the facility shall be purchased froma reputable supplier of cleaning supplies and shall belabeled as suitable for use in the food-processingindustry.Please see Example V-A on following page, and actualCleaning Schedule and Checklist now in use by averified, audited H.I.S. supplier.The cleaning chemicals shall be used according to thewritten instructions of the supplier.The hand soap used
HACCP MANUAL II. Introduction The people at Hawaii International Seafood Inc. (referred to in this Manual as H.I.S.) are dedicated to providing consistently high quality and safe seafood products. For this reason we have written this manual as a guide for our international suppliers. We
1.3 Advantages of HACCP 1.4 Application of HACCP 1.5 HACCP and Food Safety Standards 2. The Codex guidelines for the application of the HACCP system 2.1 The HACCP system 2.2 Definitions 2.3 Principles of the HACCP system 2.4 Application of the HACCP principles 3. Assemble the HACCP team - Step 1 3.1
Table of Most Likely Hazards/Control Measures for Juice VI. Preparing for HACCP A. Getting People Ready B. HACCP Training and HACCP Resource Materials 1.0 Juice HACCP Alliance Training Curriculum 2.0 USDA/FDA HACCP Training Programs and Resources Database V
Developing a HACCP Plan. The HACCP Plan must be developed specifically for the product and process implemented. Therefore, HACCP plans will vary depending on the actual product being processed. Generic HACCP plans can serve as useful guides in the development of process and product HACCP plans. However, it is essential that the unique .
processes is to provide guidance in developing a HACCP plan. 1. There must be a thorough understanding of HACCP principles when developing a HACCP plan. 2. Please refer to the "Reduced Oxygen Packaging Fact Sheet" 3. Please refer to the information sheet "What is needed in a HACCP Plan." ROP HACCP Plan must contain the following: 1.
the “standardized curriculum” recognized by FDA Training is one means to become “Preventive ontrols Qualified Individual” required by P Rules . HACCP regs FDA Juice HACCP regs USDA HACCP regs Codex HACCP Annex NCIMS Dairy HACCP art. Verification & Recordkeeping Historica
6 Certified HACCP Auditor I. HACCP System (25 Questions) A. HACCP Terminology Define, describe, and apply basic terms related to a HACCP system: 1) deviation, 2) hazard condition, 3) preventive maintenance, and describe and apply elements of 4) NACMCF (National Advisory Comm
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
The Process Flow Diagram – A Framework for the Remainder of the Official Control FCMS Study The Process Flow Diagram represents the essential framework for the FBO’s HACCP study as well as for the Official Control HACCP (OC HACCP) Study. The remainder of the OC HACCP Study is undertaken using the verified Process Flow Diagram(s) as its .
