Transcript Training GMP slideshow

GOOD
MANUFACTURING
PRACTICES
GOOD MANUFACTURING
PRACTICES
Training about our Food Safety Plan
HACCP ACRONYM
H
A
C
C
P
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azzard
nalysis
ritical
ontrol
oint
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HISTORY OF THE HACCP
SYSTEM
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 HACCP was developed in the 1960’s when NASA
asked Pillsbury to design and manufacture the first
food for space flights
 The growing concern about food safety from
public health authorities, the Food Industry and
consumers world wide has been the major force in
the introduction of the HACCP system. Today
HACCP is accepted internationally as a useful tool
for adapting traditional inspection methods to a
modern, science based, food safety system.
HACCP has become the globally recognized
method to ensure food safety
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WHAT IS HACCP?
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 HACCP is a systematic, preventative approach to food safety.
It aims to prevent biological, chemical and physical hazards,
instead of relying on finished product inspection. HACCP is
used in the food industry to identify potential food safety
hazards, so that key actions, known as Critical Control Points
(CCPs) can be used to reduce or eliminate the identified
hazards.
 With HACCP the food processor systematically:
 Identifies
Analysis).
potential
food
safety
hazards
(Hazard
 Determines the key steps in their operation where the
hazards can be prevented, eliminated or reduced to an
acceptable level. (The key steps are known as Critical
Control Points or CCPs)
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KEY CONCEPTS OF A
HACCP PLAN
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 Good Manufacturing Practices (GMPs)
 Standard Operating Procedures (SOPs)
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SOP’s ALLOW YOU TO:
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1. SAY what you do
2. DO what you say
3. PROVE it
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WHAT ARE CCPs
(Critical Control Points)?
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 A CCP is a key step where hazards
can be prevented, eliminated or
reduced to an acceptable level.
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THE SUCCESS OF HACCP AND
THE SEVEN PRINCIPLES
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1. Identify Hazards
2. Determine Critical Control Points (CCPs)
3. Establish Critical Limits
4. Establish Monitoring Procedures
5. Establish Corrective Action Procedures
6. Establish Verification Procedures
7. Establish Record Keeping
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PREREQUISITE PROGRAMS
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A. Premises (including water supply)
B. Transportation, Receiving and Storage
C. Equipment Design, Installation and Maintenance
D. Personnel Training
E. Sanitation & Pest Control
F. Recall
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GOOD MANUFACTURING
PRACTICES (GMPs)
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 You can control many of the potential hazards in
a processing plant by using a standard set of
principles and hygienic practices for the
manufacturing and handling of food. These
standard principles and practices are called
Good Manufacturing Practices (GMPs)
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GMPs ARE:
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 Preventative measures to ensure food
safety
 Based on practical experience over a long
period of time
 The foundation on which to build a HACCP
program
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STANDARD OPERATING
PROCEDURES (SOP’s)
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 The purpose and frequency of doing a task
 Who will do the task
 A description of the procedure to be performed
 What paperwork is to be completed (documentation)
 The method by which you show that task is
satisfactorily completed
 And the corrective actions to be taken of the task is
performed incorrectly
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CORRECTIVE ACTION
REQUEST
 A CAR must be
completed for each
deviation from the SOP
 CAR Form
 CAR Instructions
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 State deviation
 Use objective Evidence
 Develop an action plan
to prevent deviation
reoccurrence
 Set a deadline
 Verify that the action
plan has been
effective
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PREREQUISITE PROGRAM:
PREMISES
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 Building Exterior
 Building Interior:
Design, Construction,
Lighting, Ventilation, Waste Disposal, Inedible
Areas
 Sanitation Facilities:
Employee Facilities,
Equipment Cleaning & Sanitizing Facilities
 Water/Ice Quality and Supply
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PREREQUISITE PROGRAM:
PREMISES
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 Premises SOP
 Monitoring Procedure: part of internal
audit procedures
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PREREQUISITE PROGRAM:
TRANSPORTATION, RECEIVING &
STORAGE
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 Receiving:
Food Carriers, Temperature Control,
Approved Suppliers
 Storage:
Ingredient, Allergen, Finished Product
and Chemical Storage
 Transportation:
Food Carriers, Temperature
Control
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PREREQUISITE PROGRAM:
TRANSPORTATION, RECEIVING & STORAGE
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 Transportation Receiving and Storage SOP
 Monitoring Procedures: check each
shipment,
 CAR: example
 Allergen Program
 Approved Suppliers Program
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PREREQUISITE PROGRAM:
EQUIPMENT
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 Equipment Design and Installation
 Equipment Maintenance and Calibration
 Equipment SOP
 Temperature Monitoring Log
 Thermometer Calibration
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PREREQUISITE PROGRAM:
PERSONNEL
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 Training: Hygiene and Technical
 Hygiene and Health Requirements
 Personnel SOP
 Employee Sanitation SOP
 Visitor Log Book
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PREREQUISITE PROGRAMS:
Sanitation & Pest Control
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 SANITATION
 PEST CONTROL
 SOP
 PREOPS CHECKLIST
 TRUCK CLEANING LOG
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PREREQUISITE PROGRAM:
RECALL






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The Recall System
Complaints Log
Complaints Log SOP
Recall Template
Recall Notice
Allergen Alert Notice
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CRITICAL LIMITS
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 Is a value which separates acceptability
from unacceptability
 Critical Limits must meet or exceed
government regulations
 One or more critical limit must be met to
ensure a CCP is controlling the hazard
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CRITICAL LIMITS
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 Temperature / Time
 pH
 Aw (available water)
 Preservatives
 Available chlorine
 Sensory observations
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SOURCES OF CRITICAL LIMITS
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 Regulatory Standards
 Company Standards
 Literature Surveys
 Experimental Studies
 Expert Advice
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CRITICAL LIMITS
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 Individual Product Profiles
 Process Control Sheet
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PRODUCTION RECORDS
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 Using CIMS to record ingredients,
batch processing and finished
product information
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IMPORTANCE OF VERIFICATION
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 Ensures that all major processing steps
have been identified
 Validates the assumptions made regarding
the movement of employees and product
 Works towards continual improvement of
the GMP system
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IMPORTANCE OF VERIFICATION
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 Internal Audit
 Internal Audit Template
 Label Review
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