The SQF 2000 Food Safety Plan

Transcription

1 Definitions Terms described in the SQF Documents are defined in a Vocabulary document that is available at Words capitalized in SQF Documents (e.g. Approved Supplier) are defined in this document 2 1

2 Hazard Analysis Identifying factors in process which affect the safety of the finished product. Use the 12 steps of HACCP as a guide Conduct as a separate food safety hazard analysis Enhance control of production 3 HACCP for Food Safety 12 s 1. Assemble the HACCP Team 2. Describe Product 3. Identify Intended Use 4. Construct Flow Diagram On-site Verification of Flow Diagram Determine Scope List of all SQF Potential SystemHazards Construct Hazard Analysis Determine Control Measures The 7 Principles Principle 1 7. Determine CCPs Principle 2 8. Establish Critical Limits for Each CCP Principle3 9. Establish a Monitoring System for Each CCP Principle Establish Corrective Action for Deviations that May Occur Principle Establish Verification Procedures Principle Establish Record Keeping and Documentation Principle 7 2

3 Food Safety Hazards Food Safety Hazards can lead to serious illness of the consumer Examples: Biological E. coli O157:H7 Salmonella spp. Physical Glass in product Chemical Residues (pesticides/antibiotics/allergens) 5 Critical Control Point (CCP) Critical Control Point (CCP): 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. - Codex Alimentarius, NACMCF Any point in a process where loss of control leads to problems affecting product safety A must do 6 3

4 Control Point (CP) Any step at which biological, chemical, or physical factors can be controlled - NACMCF A step where control may be lost without presenting a significant food safety risk or, where a a food safety risk will not occur at unacceptable levels. 7 Performing a Hazard Analysis Who does it When should it be done How should it be done 8 4

5 1 Assemble the Food Safety Plan Development Team (The HACCP team) 9 Title Name Position with company Skills Team Leader Chuck E. Cheddar Director Owner; Operations Mgr for 20 years Team member Ima Farmer Administrator New Hire trainer; record keeping for 20 years Team member Handy Mann Maintenance Supervisor Equipment specialist; 2 years experience Team member Peter Brown Quality Technician QA technician, CCP Monitor Technical specialist Bob Seller Production Supervisor 15 years experience fry operator Technical specialist Jack Colby Sanitation Mgr Manages sanitation department, licensed PCO 10 5

6 2 Describe the product and its distribution 11 Product name Composition Method of preservation Inner Packaging Packaging Storage conditions Distribution method Shelf life Special labelling Customer preparation Super Sausage Patties Fully cooked frozen, not shelf stable ground pork sausage patties with dry milk powder and liquid egg Temperature control frozen storage Tray and film. Vacuum packaged. Printed inner carton, outer master case Frozen below 0 F (-17 C) Frozen transport 3-6 months under frozen conditions (0 F (-17 C)) or below; 7 days at 41F (5 C) Allergen declaration: Eggs, Milk. Keep Frozen until heating. Heat to specified time and temperature and serve 12 6

7 3 Describe the intended use and risks to consumers of the product 13 Intended use and sensitive population Intended Use Meals, snacks, sandwich fillers, add to sauces Sensitive population Those with milk and egg food allergies 14 7

8 4 Develop the flow diagram 15 Example: Super Sausage Patties STAGES STEPS in Stage 3 1 Receiving 2 3 Tempering Processing These steps are the individual tasks within Stage Mixing dry ingredients Mixing wet ingredients Mixing wet and dry ingredients Shaping of patties 4 Packaging 3.5 Cooking 16 5 Etc. Freezing Etc. 8

9 5 Confirm the flow diagram Walk the process to make sure it reflects what is happening on the processing floor Different shifts, ect Conduct a hazard analysis for each component in the process (Principle 1) 18 9

10 Hazard Analysis Example 1 Super Sausage Patties Principle 1 Hazard Cause Control Measures 3.5 Cooking Biological: Salmonella, E. coli O157:H7 Undercooking Effective Cooking Ensure staff properly trained and competent Ensure staff have proper equipment Ensure equipment has been properly calibrated 19 7 Identify the Critical Control Points (CCPs) in the process (Principle 2) 20 10

11 Food Safety Risk Analysis Matrix Consequences (Severity) Frequency (Likelihood) What is the likelihood the hazard if not controlled will lead to a serious consequence 1. Fatality 2. Serious illness 3. Product recall 4. Customer Complaint 5. Insignificant A. Common occurance B. Known to occur C. Could occur (published) D. Not expected to occur E. Practically impossible 21 Food Safety Risk Analysis Matrix Common Known to Occur Could Occur (pub.) Not expected to occur Practically Impossible Consequence Frequency A B C D E 1. Fatality Serious illness Product recall Customer Complaint Insignificant

12 Assessment of Hazard Significance A value of 1-10 indicates CCP Food Safety issues that are less significant will have value of It is up to the SQF FSPD Team to determine if control measures need to be in place (i.e. CP status control measures) or if insignificant 23 Example 1 Super Sausage Patties 3.5 Cooking step: Cooking of sausage patties 24 12

13 Example 1 The FSPD Team has proactively assessed the situation and determined step 3.5 (cooking) could pose a food safety hazard if not controlled: Potential hazard (s) Biological - Survival of pathogens: Salmonella spp., E. coli O157:H7 Cause: Survival and /or growth due to undercooking Consequence (severity): 2 (Serious illness or death, depending on age of consumer) Frequency (Likelihood): B, known to occur 25 Example 1 Common Known to Occur Could Occur (pub.) Not expected to occur Practically Impossible Consequence Frequency A B C D E 1. Fatality Serious illness Product recall Customer Complaint Insignificant

14 Example 1 Based on the results of the matrix, the team determines: Significance: 5 Control Measure(s): Effective cooking to validated cooking time and temperature Decision CCP (significant issue, falls between 1-10) 27 Example 1 Action: Cooking step is a CCP Where multiple control measures are identified to control a particular significant hazard, at least one must be a CCP. Undercooked sausage patties could result in foodborne illness to consumer 28 14

15 Hazard Analysis Example 1 Super Sausage Patties Principle 1 Principle 2 Hazard Cause Control Measures Cons. Freq. Sig. CCP/C P Reason for Decision 3.5 Cooking 29 Biological: Salmonella, E. Coli O157:H7 Undercooking Effective Cooking Ensure staff properly trained and competent Ensure staff have proper equipment Ensure equipment has been properly calibrated 2 B 5 CCP Undercooked sausage patties could result in foodborne illness to consumer Results from matrix 8 Establish and document Critical Limits (Principle 3) 30 15

16 8, Critical Limits Principle 3 Critical Limits Validation 3.5 Cooking >160 F 20 min. Research paper 1234 Time vs. Temp studies Validated time/temperature tables 31 9 Develop and document the monitoring procedures and their frequency (Principle 4) 32 16

17 9, Monitoring Where: Exit of oven How: Follow specified test procedures When: Continuous (cook time) Every batch (Internal Temp of patties) Who: Operator Principle 4 What: Cooking time through continuous temperature recording chart for each batch. Internal Temperature of patties Develop and document the corrective action procedures (Principle 5) 34 17

18 10, Corrective Action Principle Cooking Corrective Action Segregate and isolate affected product Disposition appropriately as per QA SOPs Investigate root cause of time/temperature deviation Adjust cook tunnel to achieve critical limit. Maintenance check cook tunnel for proper operation. Re-calibrate or repair equipment if needed Develop and document the verification procedures (Principle 6) 36 18

19 11, Verification What Who 3.5 Cooking Observe Operator perform monitoring check once per shift Monitor test records Monitor accuracy of temperature recording charts Calibrate thermometers Production Manager 37 Verification of Food Safety Plan Food safety plans reviewed Practitioner review of plans Hazard analysis Monitoring and corrective actions ii Verification of food safety plan Validation of critical limits Verification of CCPs Verification of CCPs being achieved Validation of food safety plan

20 HACCP Plan The completed Hazard Analysis will be documented on the HACCP Plan The HACCP Plan is structured to show that you followed the 7 Principles of HACCP 39 Principle 1 Principle 2 Hazard Cause Control Measures Cons. Freq. Sig. CCP/ CP Reason for Decision 3.5 Cooking Salmonella, E. coli O157:H7 Undercooking Effective Cooking Ensure staff properly trained and competent Ensure staff have proper equipment Ensure equipment has been properly calibrated 2 B 5 CCP Undercooked sausage patties could result in foodborne illness to consumer Results from matrix HACCP Plan P1 P2 P3 P4: Monitoring P5 P6 P7 3.5 Cooking Hazard Salmonella, E. coli O157:H7 Control Measure CCP CP Segregate and isolate CCP affected product Disposition appropriately as per QA SOPs Investigate root cause of time/temperature deviation Adjust cook tunnel to achieve critical limit. Maintenance check cook tunnel for proper operation. Re-calibrate or repair equipment if needed CL What: Where: How: When: Who: CA Verify Who, What Records 20

21 3.5 Cooking Principle 3 Critical Limits > 160 F, > 20 min. Principle 4 What Internal temperature of patties. Cooking time through continuous temperature recording chart for each batch. Where Exit of oven How Follow specified test procedures When Continuous (cook time) Every batch (Internal Temp of patties) Who Operator HACCP Plan P1 P2 P3 P4: Monitoring P5 P6 P7 3.5 Cooking 41 Hazard Salmonella, E. coli O157:H7 Control Measure CCP CP Segregate and isolate CCP affected product Disposition appropriately as per QA SOPs Investigate root cause of time/temperature deviation Adjust cook tunnel to achieve critical limit. Maintenance check cook tunnel for proper operation. Re-calibrate or repair equipment if needed CL CA Verify Who, What > 160 F, What > 20 min. Internal temperature of patties. Cooking time through continuous temperature recording chart for each batch. Where Exit of oven How Follow specified test procedures When Continuous (cook time) Every batch (Internal Temp of patties) Who Operator Records Principle 5 Principle 6 Corrective Action Verification: Who Verification: What 3.5 Cooking Segregate and isolate affected product Investigate root cause of time/temperature deviation Re-calibrate or repair equipment if needed Production Manager Observe Operator perform monitoring check once per shift Monitor test records Monitor accuracy of temperature recording charts Calibrate thermometers P1 3.5 Cooking 42 HACCP Plan Hazard Salmonella, E. coli O157:H7 Control Measure P2 CCP CP P3 CL P4: Monitoring What Segregate and isolate CCP > 160 F, affected product Internal temperature of patties. Segregate and isolate > 20 min. Disposition appropriately Cooking time through continuous affected product as per QA SOPs temperature recording chart for Investigate root cause of time/temperature Investigate root cause of each batch. deviation time/temperature deviation Where Re-calibrate or repair Adjust cook tunnel to Exit of oven equipment if needed achieve critical limit. How Maintenance check cook Follow specified test procedures tunnel for proper operation. When Re-calibrate or repair equipment if needed Continuous (cook time) Every batch (Internal Temp of patties) Who Operator CA P5 P6 Verify Who, What Production Manager Observe Operator perform monitoring check once per shift Monitor test records Monitor accuracy of temperature recording charts Calibrate thermometers Records P7 21

22 12 Develop and document the record keeping procedures (Principle 7) 43 12, Records Principle Cooking Records Time/Temperature Log Temp. Recording charts Product temp Log Thermometer Calibration Log Corrective Action Log 44 22

23 Principle Cooking Records Time/Temperature Log Temp. Recording charts Product temp Log Thermometer Calibration Log Corrective Action Log HACCP Plan P1 3.5 Cooking 45 Hazard Salmonella, E. coli O157:H7 Control Measure P2 CCP CP P3 CL P4: Monitoring Segregate and isolate CCP > 160 F, What affected product Internal temperature of patties. Segregate and isolate > 20 min. Disposition appropriately Cooking time through continuous affected product as per QA SOPs temperature recording chart for Investigate root cause of time/temperature Investigate root cause of each batch. deviation time/temperature deviation Where Re-calibrate or repair Adjust cook tunnel to Exit of oven equipment if needed achieve critical limit. How Maintenance check cook Follow specified test procedures tunnel for proper operation. When Re-calibrate or repair equipment if needed Continuous (cook time) Every batch (Internal Temp of patties) Who Operator CA P5 P6 Verify Who, What Production Manager Observe Operator perform monitoring check once per shift Monitor test records Monitor accuracy of temperature recording charts Calibrate thermometers Records P7 Time/Temperature Log Temp. Recording charts Product temp Log Thermometer Calibration Log Corrective Action Log The HACCP plan is now complete 46 23