Food Safety Systems Management

1、food safety systems management hazard analysis critical control point la systematic approach to the identification , evaluation, and control of significant food safety hazards. lrisk assessment and management tool not unlike a fmea (failure modes effects analysis). foundation of haccp - prerequisite

2、 programs haccp raw materials control sanitation facility design and control equipment design and maintenance pest control traceability and recall employee training prerequisite programs universal programs / procedures for controlling operational conditions of the plant create an environment suitabl

3、e for the production of safe products. must be adequate and effective. must be monitored (requires documentation and records) internal audit. repeated failure of a prerequisite program may indicate that decisions made in a hazard analysis are not supported. raw materials control raw materials contro

4、l lsupplier licensing and registration must meet state and federal requirements (e.g. fda registration for bioterrorism act of 2002) lmaterial guarantee and supplier certificate of insurance lsupplier food safety audit (second or third party) lraw material specifications - includes capability assess

5、ment on critical parameters lcertificate of analysis on critical to quality parameters lsupplier haccp risk assessment lhandling / shipping requirements raw materials control ldocumented inspection of sealed vehicle (temperature, sanitation) in which materials are received. lmaterials inspected upon

6、 receipt. visual inspection, grading, coa receipt, etc. as your program has defined. lsuitably stored to protect quality and integrity of goods. (allergen segregation, temperature, protected, chemicals stored separately and secured, etc). sanitation sanitation leffective cleaning procedures for equi

7、pment and facility. ldocumented ssop (sanitation standard operating procedures) ldefined frequency lchemicals approved for use in food facilities. lrecords concentrations, times, temperatures. lsanitation monitoring visual inspections, chemical or microbiological testing. lcorrective actions for def

8、iciencies. employee training employee training lrecords of training required. lhygienic practices ldisease control lcleanliness outer garments, hand-washing, unsecured jewelry and other objects, use of gloves, hair and beard nets, eating, drinking, tobacco use, nail polish, etc. lmanufacturing contr

9、ols ltraffic flow to prevent cross contamination lingredient / product handling to protect product lcontrol measures (ph, cook time / temp, moisture, etc) lscheduling sequential runs to prevent cross contamination (as for allergens) lfood defense facility design and control facility design and contr

10、ol lgrounds leliminate pest harborage areas lproperly grade roads, yards, parking lots lbuilding lprovide sufficient space for placement of equipment and storage of materials lprevent cross contamination facility design and control lfloors, walls and ceilings cleaned and in good repair. lprevent con

11、densate ladequate lighting ladequate ventilation lwater quality (potable, steam, ice, reclaimed water, cooling water, backflow prevention) lemployee welfare / sanitary facilities lwaste control lenvironmental monitoring equipment design and maintenance equipment design and maintenance ldesigned and

12、of materials and workmanship as to be adequately cleanable meets standards (e.g. 3a sanitary standards). linstalled with adequate space to allow for proper cleaning and maintenance and to prevent cross contamination. lproperly maintained (records). pest control pest control lprevention is key (desig

13、n, maintenance and sanitation) lrodent control linsect control lbird / bat control traceability and product recovery traceability and product recovery ldocumented program with written procedures to meet federal requirements. lprogram should include lproduct identification / lot coding lfinished prod

14、uct distribution records retained beyond shelf life of product lresponsible individuals and their roles lidentification of key contacts internal, supplier customer lmock recovery program lone step forward, one step back prerequisite programs are in place lets talk haccp steps to haccp implementation

15、 lassemble the haccp team ldescribe the food and its distribution ldescribe the intended use and consumers of the food ldevelop a flow diagram which describes the process lverify the flow diagram multidisciplinary haccp team lquality assurance lsanitation lengineering lmicrobiology lproduction louts

16、ide experts (if necessary) describe the food / distribution: cheddar cheese lformal product name: cheddar cheese lfood safety characteristics: ph (4.9 to 5.4) lpackaging type: 42# block, vacuum sealed in ploy bag and stored in corrugated box llength of shelf life/storage temperature: 3-12 months whe

17、n stored below 45f lwhere it will be sold: food manufacturer lintended consumers: consumers of all ages llabeling instructions: keep refrigerated lintended use: ready to eat product. may be used as ingredient. may be further processed into chunks or shredded. develop a flow diagram verify the flow d

18、iagram lhaccp team should perform an on-site review of the operation to verify the accuracy and completeness of the flow diagram. ltake the diagram out to the production floor and walk through the steps. lreview periodically, modify and update as necessary (annual review or when change to process oc

19、curs). 1 - conduct a hazard analysis lidentify hazards at each processing step and for each ingredient and material used. lbiological such as pathogen lchemical such as toxin lphysical - such as glass levaluate hazards to determine severity and likelihood to occur lthe hazard evaluation provides a b

20、asis for determining control measures such as ccps 2 - determine critical control points la critical control point (ccp) is defined as a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level. linformation from the hazar

21、d analysis should enable the haccp team to identify which steps in the process are ccps. 3 establish critical limits la critical limit must be scientifically based and is a maximum and / or minimum value to which a biological, chemical or physical parameter must be controlled at a ccp to prevent, el

22、iminate or reduce the food safety hazard to an acceptable level. lexamples: temperature, time, water activity, ph, safe tolerance level for drug residues 4 establish monitoring procedures lmonitoring is a planned sequence of observations or measurements used to assess whether a ccp is under control.

23、 lmonitoring should produce an accurate record for use in verification. lwhere there is loss of control (a ccp limit is exceeded) there must be documented corrective action. monitoring lcontinuous is desirable (recording chart) but where not possible, frequency for monitoring must be established. lr

24、esponsibility for monitoring must be assigned - position title / work station 5 - establish corrective actions lcorrective actions are procedures to be followed when a deviation occurs. lcorrective actions must be specific. lhalt production of product lisolate the affected product lreturn the proces

25、s to control ldetermine the disposition of the product lrecords must be kept for a reasonable period after the shelf life of the product 6 _ establish verification procedures lestablish procedures to verify that the system is working properly. lmight include calibration and testing of monitoring equ

26、ipment, demonstration of system performance, documented record review 7 - records lidentify records that are being used to monitor control points lrecords of training lrecords at process step (recording charts, temperature records, etc) ldeviation logs lverification and validation records lrecords t

27、o show changes to the haccp plan consider our example identify hazard at each step and for each material raw milk receiving raw milk, water 1 conduct hazards analysis lidentify the hazards for each step of the process: raw milk / receiving lidentify the type of hazard: chemical, biological or physic

28、al lchemical -lactam (antibiotic) residue, pesticide lbiological vegetative pathogens, viruses, spoilage organisms lphysical metal determine severity of each hazard and likelihood of occurrence lseverity: enteric pathogens such as e. coli 0157h7 and salmonella cause severe health effects including d

29、eath among children and elderly. llikelihood to occur: likely that they will occur in raw milk supply lusing this information, determine if this potential hazard is to be addressed in the haccp plan hazards analysis (severity) lis the hazard identified at this step severe and of sufficient likelihoo

30、d of occurrence to warrant its control? if yes, go to next question. lif no, identify the prerequisite program or procedure step, which reduces the likelihood or severity of the hazard to ensure that control at this step is not necessary. hazards analysis (control) ldoes a control measure exist at t

31、his step to prevent, reduce or eliminate the likely occurrence of the hazard to an acceptable level? lif yes, this step is a ccp. lif no, identify where control exists. (pasteurization step this step is a ccp). hazards analysis (justify) ljustification - research or reference document that gives cre

32、dence to your assumptions. pasteurized milk ordinance, 2003 revision, wdatcp 80.48 2 - determine critical control points 3 - establish critical limits lcritical limits lhtst limits for raw milk pasteurization are defined in the pmo minimum 161f / 15 seconds 4 - establish monitoring procedures lcontinuous chart monitoring of temperature and flow rate. lperformed by pasteurizer operator in the pasteurizer room. 5 - establish corrective actions lwhen minimum time or temperature requirement is not met, product automatically diverts to back to the balance tank prior to the htst pa