Implementing HACCP for GFSI

Implementation of HACCP for GFSI Schemes

Sonia Akbarzadeh, Msc, Eng.Founder & Partner

Food Industry Consulting, Inc.

Gary NowackiCEOTraceGains

Sonia AkbarzadehFounder & PartnerFood Industry Consulting, Inc.

Implementation of HACCP for

GFSI Schemes

Presented by: Sonia Akbarzadeh Msc, Eng.

Food Safety Consultant

HACCP for GFSI Schemes

GMPs in place Implementing Employees training Controlling hazards:

Personal Operations Environment

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HACCP PlanDetermine all HazardsHazards controlled by GMPsHazards not controlled by the operatorHazards not controlled by GMPs

New procedureNew MachineNew method

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CCP’s Critical hazards Critical health issueFood safety impact

EliminateReduceAcceptable levelCorrective actions

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Birth of HACCP in 1959NASA Pillsbury to produce meals for astronautsFree from:

PathogensToxins Chemical Physical

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Development of HACCP plans:

Risk based Fundamental requirement of GFSI

schemes Compliance with FSMA, CFIA

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HACCP for GFSI SchemesSuccessful HACCP planComprehensive knowledge:Incoming materials & country of originAll products Food safety characteristicsProcessesTreatmentsPackaging methodsShelf lifeStorage conditionsIntended use

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HACCP for GFSI SchemesSuccessful HACCP planAll areas of the plantStoragesEmployee restroomsLunch areasHand washing stationsChemical rooms Movement of people, ingredients, packaging

materials, chemicals, wastes, processing aids, allergens & finished product

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HACCP for GFSI SchemesSystematic gathering information & analysis1. Assemble HACCP Team2. Describe Product3. Identify Intended Use4. Construct Flow Diagram5. On-site Confirmation of Flow Diagram6. Principle 1: Conduct a Hazard Analysis7. Principle 2: Determine the Critical Control Points (CCP)8. Principle 3: Establish Critical Limits9. Principle 4: Establish Monitoring Procedures10. Principle 5: Establish Corrective Actions11. Principle 6: Establish Verification Procedures12. Principle 7: Establish Record-keeping and Documentation

Procedures9


First step is assembling HACCP Team

Assign a HACCP Leader HACCP training certificate & experience in the

fieldInclude managers of different departments Consultant as a secondary memberHACCP team training

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Step 2- Product DescriptionRelevant safety informationFinished products recipesIngredientsProcessing aidsPackaging materialList exporting countriesAllergens Restricted ingredients Country of originVulnerable ingredients 11

HACCP for GFSI SchemesStep 3- Identify the intended use of finished

products by customers RetailFood serviceFurther processingGeneral publicVulnerable population Will the food be heated by the consumerWill there likely be leftovers

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HACCP for GFSI SchemesStep 4- Construct a Process flow diagramReceiving ingredients Packaging materialsStorage of ingredients Process steps Process step numbersRecycle and rework products Introduction of packaging materials Introduction of air, water & steamCCP’s Outsourced processes & subcontracted workProcess parameters Potential for delay Finished products Intermediate/semi-processed products, by-products Low/high-care/high-risk area segregation 13


Step 5 -Verify flow diagram:

Verified by the HACCP teamAll shiftsSign and date the flowchart

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Step 6 Principle 1: Conduct hazard analysisListing all potential hazards for Ingredients,

packaging materials, processing aids & process steps, process flow & site mapPotential biological hazards Potential chemical hazards Potential physical hazards AllergensIrradiation 15


Risk Assessment

Each identified hazard likelihood of occurrence Severity Risk level

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HACCP for GFSI SchemesStep 7 _ Second Principle CCPs IdentificationMethodProcedureCritical hazard prevented, eliminated or

reduced to acceptable levelsDecision tree

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Step 8- Third Principle- CCP Critical limitsSeparate safe from unsafe products Maximum or minimum valueControl potential hazards To prevent, eliminate or reduce

physical, chemical & biological hazards

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Step 9- Fourth principle-Monitoring Procedures Observations MeasurementsWhat should be monitoredHow it should be monitoredFrequency Who

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Step 10- Fifth Principle- Corrective Actions

Deviations from the established critical limits

Prevent unsafe foods from reaching consumers

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Step 11- Sixth principle- Verification ProceduresMethodsProcedures Tests ObservationEmployee Interview

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Step 12, Seventh Principle RecordKeeping Records must be accurate Reflect the processDocument deviations Corrective actionsLogsForms Real-time data 22


Validation

Initial validationCollecting ,evaluating scientific & technical infoConducting validation studiesReviewing regulations

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Validation Annual validation Food safety incidentsRate & type of customer complaints Various auditsInternal inspections Deviation logRevalidation upon any changes

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HACCP for GFSI SchemesHACCP References The latest scientific literatureHistorical & known hazardsRelevant codes of practiceIndustry expertsGeneric modelsFood processor organizationsInformation from suppliersCustomer requirements 25

For more info please visit us:

www.food-industry.ca

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Automating Supplier

and Quality Management

TraceGains Products

Specification Publishing

Create, maintain, and publish your company’s unique specifications to ensure compliance on incoming ingredients.

Supplier Compliance

Automate lot-by-lot compliance across purchasing, COAs,

receiving, testing, and plant floor.

Finished Goods COAs

Generate finished goods COAs, manage

customer-specific formats, and send to

customers on demand.

Supplier Management

Automatically manage supplier qualification,

documents, and relationships.

Quality Management

Automate HACCP / HARPC and comply with GFSI, FSMA, safety, and quality.

TraceGains QM

To-do Lists, Alerts,Corrective Actions

Trends & Graphs

Access Anywhere,Anytime

CCPsPre-op Sanitize, Calibrate, etc.

Verify CCPs Automate FSMA, GFSI Audits & Records

GFSI Documents

FSMA, GFSI, 365 Audit Ready™

Pre-ShipmentCheckoff

Staff Training

Automation Solves Many Problems

GFSI

Labeling

FSMA

Audits

Gary [email protected]

720-465-9400www.tracegains.com

Sonia [email protected]

888-406-5554www.food-industry.ca

Implementing HACCP for GFSI

Food

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