HACCP and ISO food safety management synergies with Environmental Management System

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1 HACCP and ISO food safety management synergies with Environmental Management System Horizon 2020 Clean Technologies: Application to the food processing industry

2 Agenda 2 Food safety standard ISO22000 Environmental management ISO14001 Contacts points between the two standards Practical examples of integration of the two Practical examples of integration of the two standards from food manufacturing

3 Management system 3

4 Integrated management system Basic requirements 4 Identify and control processes Ensure that customer requirements are understood and met Purchase from suppliers that can provide quality products ISO 9001 QMS OHSAS OH&SMS ISO Food safety MS Identify food safety hazards and control critical operations Establish policy Management commitment Establish clear responsibilities Comply with the law Document compliance Control of documents and records Define competence and provide training Internal audit Prevent and correct problems Management review Emergency preparedness and response Continual improvement Identify environmental aspects and manage them Set targets and goals ISO EMS

5 Food safety within the food chain 5 Food safety hazard Any biological, chemical or physical property that may cause a food to be unsafe for human consumption. Risk assessment Hazards are analyzed in raw materials and processing steps to assess their likeliness of occurrence and potential to render food unsafe for consumption.

6 Pre-requisite programmes for HACCP 6 HACCP: Hazard Analysis and Critical Control Points GMP: Good Manufacturing Practice GHP: Good Hygiene Practice

7 Good Manufacturing Practice - GMP 7 Manufacturing processes defined in procedures and instructions Changes to the process are evaluated Adequate premises and suitable equipment are provided Operators are trained Records are made Traceability and labelling of a batch/lot Storage and distribution A system to recall any batch/lot Complaints are investigated and appropriate measures taken to prevent recurrence.

8 Good Hygiene Practice - GHP 8 Design and facilities Maintenance and sanitation Cleaning programmes Pest control systems Waste management Personal hygiene

9 Cleaning and sanitation programme 9 a. Areas and equipment to be cleaned b. Frequency of cleaning required for each item c. The specific standard procedure Instructions for handling cleaning chemicals Operator safety gear d. Equipment and methods to be used e. Chemicals or systems to be use Chemical concentrations Contact time f. The staff responsible for each task

10 Personal Hygiene Practices 10 Clean clothes, aprons Wear hat or hairnet Wash your hands before work and after unhygienic activities Avoid touching nose, mouth, and skin during food preparation No jewelery Cover all wounds on hands or arms with bright-coloured waterproof wound strip Food handlers to be free from any illnesses

11 Approaches to pest control 11 Exclusion and restriction (preventing access and denying harbourage) Seal all gaps around fittings or in walls or floors Keep the doors to the outside closed at all times Fit windows open directly into food preparation areas with screens to keep insects out Cover ventilation ducts and floor drains Inspect regularly (e.g. weekly) for sign of pests both outside and inside Check incoming foods and supplies for sign of pests Store food and supplies properly: Cover them properly Store them at least 15cm off the floor and 15cm/ away from walls Store and remove garbage properly and regularly. Keep garbage covered. Destruction Use chemical, physical or biological means, e.g., rodent traps, where there are sign of pests Use a zapper or insecticutorto capture and kill flying insects. Ensure zappers are not above or within 3 metres of a food preparation or storage area. Avoid spraying insecticide over food preparation surfaces. Hire a professional pest control company if necessary.

12 Pest control programme 12 Name of contact person Name of extermination company List of pesticides used and the relevant Material Safety Data Sheets Map of bait locations and electric insectocutors Frequency of inspection Pest survey and control reports

13 HACCP principles Conduct a hazard analysis 2. Determine the critical control points (CCPs) 3. Establish critical limits for each CCP 4. Establish a monitoring system for each CCP 5. Establish the corrective action to be taken when a particular CCP is not under control 6. Establish procedures for verification that the HACCP system is working effectively 7. Establish documentation concerning all procedures and record keeping

14 Conduct a hazard analysis 14 Assemble a HACCP team Describe the products State the intended use Draw a flow diagram Confirm the accuracy of the flow diagram Image: Suat Eman / FreeDigitalPhotos.net Carry out hazard analysis Identify all potential hazards associated with each step Evaluate each hazard in terms of likelihood of occurrence severity of the effect

15 Example of a beef slaughter process flow diagram 15 Image: Tim Beach / FreeDigitalPhotos.net

16 Example of a beef HACCP plan 16 Stage Hazard Type of hazard/comment Control measures Relevant program Cattle receiving and holding C: Yes P: Yes B: Yes C: Chemical residues P: Needles etc. B: Human pathogens/parasites On-farm program Ante-mortem inspection On-farm program Dehiding C: No P: No B: Yes B: Transfer of faecal matter from the hide onto the carcass Sterilize all equipment Check for faecal material and stains GHP SOP Trimming (to remove excess fat) C: No P: No B: Yes B: Crosscontamination of carcasses Place the knives in water at temperatures of at least 82 C GHP Hazards: C: Chemical P: Physical B: Biological

17 Example CCP: Visual carcass contamination inspection 17 Contaminants, for example faecal and/or blood, found on the carcasses may be detected by visually inspecting the carcasses. Critical limits There should be no visual evidence of contamination on any of the carcasses. Monitoring All carcasses should be checked. Corrective action(s) Trimming off the affected area of the carcass and then returning the carcass to the slaughter line for re-inspection.

18 Summary of CCP monitoring and records 18 Hazard Critical limits Monitoring procedures What How Freq Who Control measures Corrective action Records Verification Growth of food poisoning bacteria At least C inside the chamber for at least 6-8 seconds Steam pasteurisation Temperature in the chamber Automatic Continuous N/A Daily, Corrective actions Re-route affected carcass through pasteurisation unit Validation record review Monthly audits Microbial tests Growth of food poisoning bacteria Chilling 7 C or less within 24 hours & maintain Deep round muscle temperature Temp probe or automatic 1 hour or continuous Quali ty Assur ance Carcass re-chilled until 7 C or less obtained. Repair chillers Hourly, Corrective actions Validation record review Monthly audits Microbial tests

19 Initiation of a recall/withdrawal 19 To minimise risk, recalls/withdrawals should be carried out in the shortest time practicable Develop recall/withdrawal procedure and test it Information for the product recalled/withdrawn Name of intended recipient of notification Product name Packaging information Batch and lot number(s) and expiration date Date and method of recall/withdrawal Reason for recall/withdrawal (problem/defect) Manufacturer s name and address and contact information Follow-up Causes leading to the recall/withdrawal Quantity of stock returned and proposed method of disposal Actions to prevent a recurrence

20 Managing environmental aspects 20 All identified aspects (ressource use, emissions etc.) Significant aspects Prioritised aspects Objectives and targets - Aspects selected for continuous improvement Operational control - Aspects to be maintained at the same level Emergency response Aspects in the event of an emergency situation

21 Ranking of significant aspects 21 Environmental concerns (ISO 14004): The scale of the impact The severity of the impact Probability of occurrence Duration of impacts Business concerns (ISO 14004): Regulatory and legal Difficulty of changing the impact Cost of changing the impact Effect on other activities and processes Concerns of interested parties Effect on the public image Example Ranking = quantity x impact Quantity Impact 1. Small 0. No impact 2. Medium 1. Small 3. Large 2. Medium 3. Large

22 Contacts points between the two standards 22 Making Complaint Records Establish complaint procedures Document all complaints from customers/neighbours Record details including the date, customers/neighbours details, reasons and response for complaint and corrective actions

23 Waste disposal food safety 23 Waste disposal bins placed around the working area of food preparation rooms Waste disposal bins clearly distinguishable from other storage bins Waste disposal bins in food preparation rooms need not be covered if they are in frequent use and are regularly emptied. Preferably, use bins with a pedal Defined area allocated for the storage of waste pending disposal When food waste is removed from food preparation rooms pending disposal, it must be placed in a tightly covered waste storage bin Plastic liners in waste disposal and storage bins Waste disposal and storage bins emptied when full or on a regular basis Waste disposal bins cleaned and sanitised daily and placed upside down and off the floor to drain overnight Image: Victor Habbick / FreeDigitalPhotos.net

24 Waste disposal environment 24 Priorities Reduce Recover Reuse/Recycle Segregation For recycling Hazardous waste Labelling Storage Spill prevention Compaction Authorized waste handlers Image: Victor Habbick / FreeDigitalPhotos.net

25 Example of integrated work instruction 25 Process Food safety Health and safety Environment Sanitize equipment 5% solution of XX applied on all surfaces and left in contact for 15 min. before rinsing with water Use protective gloves Data sheet XX

26 References 26 Standards Food safety management systems - Requirements for any organization in the food chain (ISO 22000:2005) Environmental management systems - Requirements with guidance for use (ISO 14001:2004) Environmental management systems - Requirements with guidance for use (ISO 14001:2004/Cor 1:2009) CAC/RCP General Principles of Food Hygiene

27 References 27 Examples Development of Pre-requisite Programmes and HACCP Principles for Irish Beef Slaughterhouses Auditing of Pre-requisite Programmes and HACCP Principles in Irish Beef Slaughterhouses Centre for Food Safety - Booklet - How to Implement a Food Safety Plan ccp/programme_haccp_industry_safe.html

28 About us 28 EXIMA is a service provider to global industry linking cost reductions and CSR Offices in Denmark and Italy Global network of resource efficiency experts Subscriber to UN Global Compact initiative Registered supplier to the World Bank on Cleaner Production

29 Contact 29 Tel.:

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