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GMP / HACCPTraining Manual1

Our Companyis committed to the development andimplementation of GMPS following theprinciples of HACCP.2

GMP Implementation andManagementWho’s involved – everyoneLead Hands are the key3

What is a GMP/HACCPProgram? Good manufacturing programs/Hazard AnalysisCritical Control Point- A system which identifies specific hazards andpreventative measures for their controlPrograms to manage food safety. An internationally recognised program (Codex).A program designed to be specific to a food facility.A program that requires corporate commitment.A program that requires the commitment of each employee.4

HACCP Program A HACCP program has three components1. GMP (Prerequisite Programs)2. HACCP Plan3. Verification Program5

GMP ProgramOur Company is focusingonGMPs at this time.6

GMPS vs CCPs GMPs (Prerequisite Programs)control the environment that a food isproduced in and the practices of theemployees CCP (Critical Control Point)a point or process (manufacturing control)in the operation which is designed tocontrol a specific hazard.7

Hope All Companies Control Products & Processes8

Origin of the HACCPConcept The concept of a HACCP Program wasoriginally developed and implemented inthe 1960’s by the Pillsbury Company. It was developed to ensure safe foods forNASA and the Apollo program bycontrolling the environment and theprocessing parameters.9

What are the Benefits ofGMPs & HACCP ? A formalized safety management system basedon good science. A higher level of understanding and participationof employees. Demonstrates due diligence and definesresponsibilities. Builds client and consumer confidence.10

Benefits of GMP Consumer confidence – Regulatory Compliance Industry Consistent quality and prevent rere-work Increased efficiency Marketing toolGrow businessJob security11

What doesGMP/HACCP do ? GMP/HACCP provides an auditablesystem for food safety. GMP/HACCP requires a plan whichdictates how a company manages food safety. GMP/HACCP requires companies to properlydevelop prerequisite programs (GMP) which detailhow hazards may be controlled. GMP/HACCP requires critical control points to beestablished to control hazards not controlled by aprerequisite program.12

GMP/HACCPand the Employee GMP/HACCP will require the employee tounderstand the aspects of food safety inrelationship to the tasks he or she performs. GMP/HACCP puts the responsibility of controllinghazards on the person performing the task. GMP/HACCP will prompt the employee to takecorrective action before a deviation becomes aproblem. GMP/HACCP requires employee commitment toperform their tasks as trained.13

Food Safety Food safety cannot be achieved by governmentregulations and inspection, it can only be achieved bycareful handling of foods at all points in the food chain,from production to consumption. Food handlers must understand their role and acceptthe responsibility of their actions. It is the foodhandlers responsibility to provide safe, wholesomefoods to the customer. It is also the food handlers responsibility to maintain thequality and reputation of their companies products andor services.14

Food Protection Proper controls are necessary to preventcontamination of food which may result in apotential health hazard. Control of critical points in the handlingsequence of food is essential for the protectionof food. Control can be achieved through corporatecommitment and the planning andimplementation of a sound, effectiveGMP/HACCP program.15

Characteristics of Food Internal characteristics available nutrientsavailable waterpH (acidity or alkalinity)physical structure External characteristics temperatureatmosphere (presence or absence of O2)packaging16

Temperature and Time Time and Temperature are the most importantfactors in the spoilage and safety of food. Temperature affects the rate at whichmicroorganisms grow. Food handlers control temperature17

HA - Hazard Analysis Hazard: The potential to cause harm. All food ingredients, food and processes areanalyzed for three types of hazards:– Biological– Chemical– Physical Hazards may be– a cause– or a factor in food safety18

Sources of Hazards Workers Ingredients & Materials Equipment Processes Building19

Hazards from Source Workers Biological– skin, nail, hair– colds, sores– clothing Chemical– soaps, grease, chemicals Physical– jewellery, clothing, pens20

Hazards from Source Ingredients & Materials Biological– microorganisms associated with ingredients &materials– contamination Chemical– allergens– chemical contaminants Physical– foreign materials21

Hazards from Source Equipment Biological– poor sanitation procedures– airflow Chemical– lubricants– cleaning material– exhaust Physical– metal filings– parts22

Hazards from Source Processes Biological– cross contamination– inadequate heat treatment– inadequate storage temperatures Chemical– boiler chemicals in steam– chemical residues Physical– foreign material23

Hazards from Source Building Biological walls, floors, openings, storagecondensation, waterpestsemployee flow Chemical– storage of chemicals– ventilation Physical– glass, metal, wood24

CCPCritical Control Point CCP: A point, step or procedure at which control canbe applied and a food safety hazard can be prevented,eliminated, or reduced to acceptable levels. Examples of a CCP freezerfryermetal detectorlabel– Critical Limit: A value which separates acceptabilityfrom unacceptability25

Biological HazardsHow do they become a problem in food ? Contamination Uncontrolled conditions inadequate cleaninginappropriate facilitiesuncontrolled temperaturesovercrowding of storage product exposed to moisture from other foodspeople - hygienepestsequipment & utensilsInadequate destruction ineffective sanitation, programs and traininginadequate heat treatment26

Controlling BiologicalHazards Temperature control Keep out of the Danger Zone40C - 60 0C. Keep frozen food below -18 0C Atmosphere controlNutrient controlMoisture controlPrerequisite programs (GMP)27

Microorganisms Bacteria Moulds Virus ParasitesGrow in foodDo not growin food Sources people, animals, insects, food, food surfaces,packaging, soil, water, air28

How Bacteria GrowMultiply by Dividing - every 20 minutes29

Bacterial Growth If one bacteria was present on a food at 9 A.M. and wasallowed to grow in optimal conditions with enough foodat 10 A.M. there would be 8Noon5124 P.M.2 million7 P.M.1 billionafter 48 hrs.2114 This mass would weigh 4000 X the weight of our planet.30

Chemical Hazards Cleaners & sanitisers residueChemicals - lubricants & paintNatural toxins - aflatoxinAllergens - eggs, nuts, milk, peanuts31

Chemical Hazards How do they become a problem in food ? Contamination from other foods residues equipment & utensils Uncontrolled conditions inappropriate or lack of SOPsinappropriate storage facilitieslack of specifications and QCovercrowding of storage32

Controlling ChemicalHazards Appropriate SOPs. Appropriate prerequisite programs.33

Physical Hazards Injurious Extraneous Matter (IEM) Risk is based on hardness, sharpness, size or shape. Examples of IEMmetal glass stones jewellery wood plastic 34

Physical Hazards How do they become a problem in food ?– Contamination –misuse of packagingbroken glassfrom ingredientspalletsphysically damaged productline breakdownsUncontrolled conditions inappropriate or lack of SOPsinappropriate storage facilitieslack of specifications and QC35

Controlling PhysicalHazards Magnets Metal detectors X-ray Appropriate SOPs. Appropriate prerequisite programs.36

Prerequisite Programs Premises Receiving / Storage Equipment Performance & Maintenance Personnel Training Programs Sanitation Health and Safety Recalls37

Premises Outside property free of debris & refuse proper roadways and drainage Building permit cleaningprevent entrance and harbourage of pestsprevent entrance of environmental contaminantssound construction and good repair Sanitary facilities washrooms, lunchrooms and change rooms handwashing and sanitising facilities equipment cleaning and sanitising facilities Water quality and supply program38

Receiving / Storage Receiving of raw materials, ingredients, foodproducts and packaging Specifications & conformance Storage Temperature and humidity controlsOf raw materials, ingredients, food products and packagingOf finished food productsOf damaged and or returned goodsOf non-food chemicals39

Receiving Food and packaging must be inspected onarrival. Reject product not meeting specification. ALL FROZEN and REFRIGERATED FOODSMUST BE PUT INTO PROPER STORAGEIMMEDIATELY. STORE FOOD IN SUCH A MANNER AS TOAVOID CROSS-CONTAMINATION.40

StorageStore all perishable foods below 4oC.Store all frozen food at or below - 18oC.Follow the FIFO (First In First Out) rule.Keep all food 15cm (6") off the floor & 46cm(18") between rows. Store products according instructions. Code all cases for easy ID, store accordingly. 41

Equipment Performance& Maintenance Equipment design Equipment installation Equipment maintenance Equipment calibration Preventative maintenance42

Personnel Training Manufacturing controls Hygienic Practices Communicable diseaseInjuriesWashing of handsPersonal cleanliness and conductControlled access43

Hygiene The development and maintenance ofconditions or practices conducive to goodhealth. Generally regarded as personal cleanlinessand habits.44

Handwashing Before starting work.After using the toilet.After touching your hair, ear, nose, mouth.After sneezing, coughing scratching.After eating smoking.After handling a food and before handling another.Before leaving or returning to your work station.After handling garbage and cleaning up.45

Handwashing To reduce or eliminate transientflora (Microorganisms) Hands, nails and exposed areas ofarms for 30 seconds using soapand under running water.46

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Hygiene Use hair restraints. Garments, aprons and shoes must becleaned and changed as necessary.49

Sanitation Sanitation Program Adequacy Adherence Pest Control Program Adequacy Adherence50

Sanitation The development and maintenance of hygienic healthsupportive conditions. Generally regarded as the cleaning and disinfecting offood handling surfaces and facilities.51

Sanitation ProgramAreas that must be included in a cleaning program: food storage areas, equipment and work surfaces.toilet and hand washing facilities.lockers, dressing rooms, and lunchroom facilities.storage of clean and soiled linens, clothing and cleaning cloths.garbage and refuse disposal materials and areas.storage of cleaning compounds (poisonous and toxic materials).floors, walls and ceilings.ventilation.lighting.receiving area.entrance, parking lot.52

Cleaning and Sanitising Rinse surfaces with warm water. Wash and scrub as necessary using anapproved cleaner as directed in the SSOP. Rinse surfaces with warm water. Sanitise using an approved sanitiser as directedin the SSOP. Time and temperature are critical in cleaning andsanitation.53

Pest Control Eliminate entry ways. Eliminate habitats and food supplies. Destroy or catch those that gain entry. Regular inspections Sound well documented pest control program54

Pest ControlRemember 1 fly leads to 9001 cockroach leads to 30 - 401 moth leads to 4001 beetle leads to 3751 rodent leads to 30Pesticides and rodentcides can only be appliedby certified technicians.55

Recall Recall System Recall Initiation56

Line Responsibilities inGMP/HACCP Follow and understand the SOPs for yourtasks. Understand your responsibilities and role incontrolling a GMP/CCP in your area. Monitor CCPs and Prerequisites. Take prescribed or approved correctiveaction when needed to maintain control. Document corrective action Verify GMP/HACCP program is workingcorrectly and document57

An IneffectiveGMP/HACCP Program Results in improper handling of foods: Consumer illness or dissatisfactionConsumer emotional traumaCustomer dissatisfactionunfavourable publicityincreased customer & consumer complaintsloss of volume and profitsliability claims, lawsuits and criminalprosecution (legal and court costs)high insurance costsfood spoilage -product loss - dollar lossunsanitary conditions58

An IneffectiveGMP/HACCP Program Which may lead to: loss of customers & markets negative employee attitudes absenteeism retraining even layoffs59

Documentation An extremely important part of GMP isdocumentation of every aspect of theprocess, activities, and operationsinvolved60

Documentation Why is documentation and recordkeeping important:–––––To be clear about what you do and how you do itTo confirm that you have done it correctlyTo show proof of process – due diligenceTo identify non compliances and deviationsTo assist in planning corrective action61

Benefits of GoodDocumentation Provide basis for training and qualification ofstaff Provides for consistent operation Provides a starting point for processimprovement Provides a “Paper Trail” – A starting point forproblem resolution62

Remember Do as you say,Say as you do !Do it !63

Hard Agonising Confused Complicated Paperwork64

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GMP/HACCP Test6) The line employee will be responsible fora) controlling CCPs.b) monitoring CCPs.c) take corrective action when needed tomaintain control.d) all of the above.1) GMP/HACCP isa)b)c)d)a way of testing food.a system to manage food safety.developed by Health Canada.all of the above.2) A critical control point isa) an acceptable level of risk.b) where control can be applied to prevent or reduce a safety hazard.c) where loss of control may result in an unacceptable food risk.d) both b and c.7) Hazards are generallya) chemical.b) biological.c) physical.d) all of the above.3) Which are potentials for hazardsa) no process to control microorganisms or chemicals.b) ingredients are a possible source for microorganisms.c) abuse in distribution and storage.d) all of the above.8) Physical hazards may includea) stones.b) wood.c) glass.d) all of the above.9) Chemical hazards may includea) pesticides.b) cleaning and sanitizing compounds.c) allergens.d) all of the above.4) What is the key to a successful GMP/HACCP program?a) hazards.b) temperature control.c) corporate commitment.d) product testing.10) Benefits of a GMP/HACCP program include?a) a formalized food safety system based ongood science .b) higher levels of understanding andparticipation of employees.c) demonstrates due diligence.d) all of the above.5) GMP/HACCP isa) the responsibility of all employees.b) will require the commitment of all employees.c) will prompt the employee to take corrective action.d) all of the above.66

GMP / HACCP Training Manual . 2 Our Company is committed to the development and implementation of GMPS following the principles of HACCP. 3 GMP Implementation and Management

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