HACCP System / Manual Review

March 2011

New Products / Process.

Pre-packed Marinated products in skewers started supplying to Carrefour outlets in Dubai / Abu Dhabi / Al Ain / Ajman / RAK.

Pre-packed Marinated / Non- marinated products to butchery counter.

Marinated chicken products under Modified atmosphere packing (MAP) Approval from Ajman / Sharjah not granted due to absence of process guidelines for this kind of packed products. Abu Dhabi Food control granted approval for 3 days shelf life.

HACCP System / Manual Review 2011

Supplier Approval Program

We had reviewed the existing suppliers list (over seas & local). Many new suppliers (local) included in the approved suppliers list. Most of the local suppliers had been graded as Grade C due to non-receipt of the supplier self evaluation form and other relevant documents.
Grading:GRADE A - If the supplier has any of these system - HACCP / SQF / ISO22000:2005 / or any other international accreditation. GRADE B If the supplier has any in-house food safety or quality system / in process of any food safety/quality system / any verification program / reputation of the supplier with Farm Fresh in terms of quality compliance & product complaints received for the product supplied. GRADE C - Reputation of the supplier with Farm Fresh in terms of quality compliance / Volume of the products supplied / Product complaints received for the product supplied.

HACCP System / Manual Review 2011

New Food Transport Vehicles

Two new Food transport vehicles added to the existing fleet to help delivery constraints. The same were approved by DMFCS
HACCP Operational Manual up-dating

There was no major changes in the process flow or products and all the appropriate changes in regard to documentation and amendments were incorporated in the existing HACCP operation Manual.

HACCP System / Manual Review 2011

In-house Training

We had completed Basic Food Hygiene training (for the year 2010) for new staffs involved in food handling and DM attested certificates provided. Refresher Food Hygiene training 2010 for all staffs involved in food handling had completed and certificates provided. Training calendar for 2011 We shall have the Refresher Food Hygiene training in the month of July / August with a batch strength of 20 staffs. Training will be conducted in Fridays during the above said period. PIC training Will be conducted accordingly upon finalisatation of the staff and approval from Management.

HACCP System / Manual Review 2011

PIC Person In Charge Training

DM FCS has implemented new program called PIC Person In Charge for every food establishment in the Emirate of Dubai. The implementation lead time is Dec 2011. This is mandatory for all food establishments operating in Dubai. There should be one PIC through out the operation (each shift). Person in Charge means a person directly responsible for the food related operations in the food establishment and has direct authority, control or supervision over employees who engage in the storage, preparation, display, or service of foods.

HACCP System / Manual Review 2011

PIC Person In Charge

Person in Charge Certified in Food Safety means a Person in Charge, who has successfully completed a food safety course appropriate to the type of food business.
Person in Charge training can be provided by in-house trainer and after finishing the training, staff need to appear for an exam with an external certificate awarding company which is approved by DM. Upon passing the exam fully completed a food safety course appropriate to the type of food business. We need to have 3 PICs from ware house and processing. As one in each shift and one will be back-up.

HACCP System / Manual Review 2011

Microbiology analysis results summary for 2010. Food samples test results

By adhering to the implemented HACCP system Food samples compliance percentage registered as 100% (94 tested & NO non-compliance)
Year Tested noncompliance compliance compliance %

2010 2009

94 92

94 89

0 3

100 96.74

(grading as per in-house system)

HACCP System / Manual Review 2011

Microbiology analysis results summary for 2010. Hand swab test results

By maintaining strong personal hygiene code maximum hand swab test result graded as GRADE A+ & A A+ 31 A 14 B+ 12 B 12 C+ 11 C 3 Total 82

(grading as per in-house system)

HACCP System / Manual Review 2011

Microbiology analysis results summary for 2010. surface swab test result

By following & monitoring good cleaning & sanitation practice maximum surface swab test result graded as GRADE A+ & A
A+ 12 A 13 B+ 8 B 2 C+ 1 C 0 Total 36

(grading as per in-house system)

HACCP System / Manual Review 2011

Microbiology analysis results summary for 2010.

Water samples test result

By maintaining good sanitation of water holding tank & pipelines all the water samples test result graded as GRADE A+ & A
TOTAL 12

A+
3

A
3

B+
4

B
2

C
0

(grading as per in-house system)

HACCP System / Manual Review 2011

Customer Complaints
SR 4 7 IHR 5 1 NA 0 2 SR/IHR 2 0 Total 11 10

2009 2010

HACCP System / Manual Review 2011

Internal & External audits

In monthly HACCP audits our compliance evaluation remained GOOD, how ever few observations were raised in view of continuous improvement. In DMFCS inspections in 2010, our inspection compliance GRADE maintained consequently as GRADE B with 83 to 87 points. In SGS HACCP certification/surveillance audits our compliance observed as satisfactory with very few observations were raised in view of continuous improvement.

HACCP System / Manual Review 2011

Internal & External audits

In the audits carried out by our customers in their Supplier Audit our compliance scale remained GOOD with out any MAJOR/CRITICAL non-compliance. Our customers rated Farm Fresh as their Approved Supplier. To list few potential customers EKFC, Carrefour, Abela..

HACCP System / Manual Review 2011

Personal Hygine Motivation Program

In view of bringing the existing personal hygiene compliance to next higher level, we had introduced and implemented Personal hygiene motivation program. Initially this program is introduced within processing unit staffs, as personal hygiene in this environment is at prime importance. Each staff is monitored and evaluated on daily basis and at the end of each month, staff scoring highest points are awarded with certificate of Appreciation as personal hygiene staff of the month and the staff scoring 1st, 2nd, 3rd, 4th for entire year will be awarded a special certificate. This motivation program was intimated from November remarkable improvement observed with in short period. 2010,

HACCP System / Manual Review 2011

Personal Hygine Motivation Program

Grade Nov-10 Dec-10 Jan-11 Feb-11 a++ 1 0 14 16 a+ 0 7 10 12 a 7 8 1 1 b+ 15 7 3 1 b 8 8 2 1 c+ 1 3 1 0 c 1 0 0 0 d 0 0 0 0 Vacation 1 0 2 1

(grading as per in-house system)

HACCP System / Manual Review 2011

Management Support & Team Farm Fresh Effort.

With strong management commitment and support Team Farm Fresh performed well in maintaining the implemented HACCP - Food Safety System. With each individual continuous effort Team Farm Fresh maintains the success of compliance and viability of implemented HACCP Food Safety System.

HACCP System / Manual Review 2011

Thank You.

HACCP System / Manual Review 2011