The Global Food Safety Initiative and Supporting Good Manufacturing Practices Jason Fletcher Eastman Chemical Company Global Quality March 25, 2014

Transcription

1 The Global Food Safety Initiative and Supporting Good Manufacturing Practices Jason Fletcher Eastman Chemical Company Global Quality March 25, 2014 I

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3 Problems within the food supply chain: Significant recalls Negative publicity Increased global economy Too many audits for food suppliers

4 What is GFSI? Global Food Safety Initiative a rigorous scheme developed by leading food companies for ensuring food safety Reduce food safety problems Manage cost in the global food system Develop consistent and competent food safety systems Create network to exchange best practices

5 Companies that are GFSI certified:

6 Approved GFSI Certifications Certified via independent 3 rd party certifying body Certifying body must be accredited GFSI Scheme Food Safety System Certification - FSSC British Retail Consortium - BRC International Featured Standards - IFS Safe Quality Food - SQF Global GAP (Good Agricultural Practices) Canada GAP Primus GFS (Global Food Safety) Global Red Meat Standard - GRMS Global Aquaculture Alliance - GAA IFS PAC Secure Food Market General Food Safety Management Agriculture Fresh Fruits and Vegetables Agricultures Crops Red Meat Seafood Food Packaging

7 GFSI Key Elements Food Safety Management System Hazard Analysis Critical Control Point Plan Good Manufacturing Practices (GMP s) or Prerequisite Programs

8 Food Safety Management System (FSMS) Food safety team (FST) FST leader Management commitment and support Effective communication (internal and external) Documents and records for food safety programs Change control systems (MOC) Training Internal audits Continuous improvement

9 HACCP HACCP (Hazard Analysis Critical Control Point) identifies and evaluates the food safety risks of the finished product. Risk assessment is conducted on every step of the manufacturing process, from the receipt of raw materials to the shipping of finished product. Biological E. Coli, Salmonella, Listeria Chemical Toxins, Detergents, Allergens Physical Bone, Shells, Metal Each risk is evaluated based on severity and likelihood to determine overall impact on the consumer.

10 HACCP Risk Categories and Control Plans Low Risk General Good Manufacturing Practices (GMP s) or Prerequisite Programs (PRP s) Examples: pest control and housekeeping programs Risk Specific PRP Operational Prerequisite Programs (OPRP s) High Risk Critical Control Points (CCP) Examples: Metal detection, microbial analysis, heavy metals testing.

11 Control Plans for CCP and OPRP A control plan is required for OPRP s and CCP s and must include: Action taken to address the OPRP or CCP risk Acceptance criteria Who is responsible for executing control plan What to do if product fails acceptance criteria What is the disposition of affected product How is the control plan documented CCP s require validation and specialized training

12 Managing the HACCP Plan Reviewed at least annually Reviewed for major changes HACCP Coordinator manages the plan (typically same person as the FST leader) HACCP team established and includes multiple disciplines responsible for the food product: Production Quality Assurance Engineering Laboratory Maintenance Legal/Product Safety

13 Good Manufacturing Practices (aka Prerequisite Programs) The main role for the GMP s is to prevent contamination of the food product which may be introduced via: Pests Human contact Maintenance activities Improper handling Intentional adulteration Environment

14 Proper Construction and Layout Durable construction materials Proper design to prevent food hazards and contamination Materials of construction are not reactive to the food product Keep the food safety system as closed as possible

15 Adequate Utilities Air, Water, Energy Water supply and quality (potable) Boiler chemicals are food grade Proper air quality and ventilation (filters) Adequate electricity and lighting

16 Preventive Maintenance Program Critical food safety equipment needs to be identified and routinely checked to ensure proper operability: Refrigerators Thermometers Metal detectors Product filtration systems HVAC systems Repairs and preventive maintenance should be done in a manner that doesn t introduce contamination.

17 Cleaning and Sanitizing Use the right cleaning and sanitizing agents Develop cleaning and sanitizing programs to ensure consistent practices Master cleaning schedule (MCS) Cleaning in place (CIP) systems Inspect to ensure effectiveness

18 Pest Control Pest control program established Preventing access to pests Seal up cracks and spaces (doors) Monitoring and detection Eradication for infestations Timely handling of trash

19 Management of purchased materials Approval process for new suppliers Specifications to include requirements Monitor suppliers Inspect all incoming raw materials Complaint system exists for nonconformances Includes raw materials and packaging X

20 Prevention of Cross Contamination Microbial contamination Allergen management Physical contamination Cleaning compounds Equipment lubricants

21 Personal Hygiene and Employee Facilities Hand washing stations Designated break areas Adequate facilities (restrooms) Clean work wear and protective clothing Good health status of employees Personal cleanliness Personal behavior

22 Good Storage Practices Warehouse requirements FIFO (First In First Out) Segregate materials Good housekeeping Delivery practices Container inspections Previous cargo consideration Container cleaning Protection from contamination during transit

23 Food Defense This is conducted to prevent intentional adulteration (Food safety prevents unintended contamination) Access control Background checks Tamper-evident sealing for finished product and incoming materials Site security measures Facility must have a Food Defense Program in place

24 Consumer Information and Awareness Food safety information must be communicated to consumers: Labeling Storage guidelines Food preparation instructions Expiration date (shelf life) Allergen communication

25 Product Recall Procedures Key contacts for customers are maintained Ensure traceability for all aspects of the process, including raw materials Mock recalls must be routinely conducted to test the system how long did it take degree of traceability Anticipate different recall situations Document results and identify improvement opportunities

26 Questions?