GOOD

MANUFACTURING
PRACTICES

GOOD MANUFACTURING
PRACTICES
Training about our Food Safety Plan

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MANUFACTURING
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Good Management Practices Dec-07
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HACCP ACRONYM
H azzard
A nalysis
C ritical
C ontrol
P oint
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HISTORY OF THE HACCP
SYSTEM
HACCP was developed in the 1960s when NASA
asked Pillsbury to design and manufacture the first
food for space flights

The growing concern about food safety from
public health authorities, the Food Industry and
consumers world wide has been the major force in
the introduction of the HACCP system. Today
HACCP is accepted internationally as a useful tool
for adapting traditional inspection methods to a
modern, science based, food safety system.
HACCP has become the globally recognized
method to ensure food safety
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WHAT IS HACCP?
HACCP is a systematic, preventative approach to food safety.
It aims to prevent biological, chemical and physical hazards,
instead of relying on finished product inspection. HACCP is
used in the food industry to identify potential food safety
hazards, so that key actions, known as Critical Control Points
(CCPs) can be used to reduce or eliminate the identified
hazards.

With HACCP the food processor systematically:
Identifies potential food safety hazards (Hazard
Analysis).
Determines the key steps in their operation where the
hazards can be prevented, eliminated or reduced to an
acceptable level. (The key steps are known as Critical
Control Points or CCPs)


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KEY CONCEPTS OF A
HACCP PLAN
Good Manufacturing Practices (GMPs)

Standard Operating Procedures (SOPs)
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SOPs ALLOW YOU TO:
1. SAY what you do

2. DO what you say

3. PROVE it
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WHAT ARE CCPs
(Critical Control Points)?
A CCP is a key step where hazards
can be prevented, eliminated or
reduced to an acceptable level.
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THE SUCCESS OF HACCP AND
THE SEVEN PRINCIPLES
1. Identify Hazards
2. Determine Critical Control Points (CCPs)
3. Establish Critical Limits
4. Establish Monitoring Procedures
5. Establish Corrective Action Procedures
6. Establish Verification Procedures
7. Establish Record Keeping

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PREREQUISITE PROGRAMS
A. Premises (including water supply)
B. Transportation, Receiving and Storage
C. Equipment Design, Installation and Maintenance
D. Personnel Training
E. Sanitation & Pest Control
F. Recall


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GOOD MANUFACTURING
PRACTICES (GMPs)
You can control many of the potential hazards in
a processing plant by using a standard set of
principles and hygienic practices for the
manufacturing and handling of food. These
standard principles and practices are called
Good Manufacturing Practices (GMPs)
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GMPs ARE:
Preventative measures to ensure food
safety

Based on practical experience over a long
period of time

The foundation on which to build a HACCP
program
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STANDARD OPERATING
PROCEDURES (SOPs)
The purpose and frequency of doing a task
Who will do the task
A description of the procedure to be performed
What paperwork is to be completed (documentation)
The method by which you show that task is
satisfactorily completed
And the corrective actions to be taken of the task is
performed incorrectly
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CORRECTIVE ACTION
REQUEST
A CAR must be
completed for each
deviation from the SOP
CAR Form
CAR Instructions



State deviation

Use objective Evidence

Develop an action plan
to prevent deviation
reoccurrence

Set a deadline

Verify that the action
plan has been
effective

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PREREQUISITE PROGRAM:
PREMISES
Building Exterior

Building Interior: Design, Construction,
Lighting, Ventilation, Waste Disposal, Inedible
Areas

Sanitation Facilities: Employee Facilities,
Equipment Cleaning & Sanitizing Facilities

Water/Ice Quality and Supply
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PREREQUISITE PROGRAM:
PREMISES
Premises SOP

Monitoring Procedure: part of internal
audit procedures


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PREREQUISITE PROGRAM:
TRANSPORTATION, RECEIVING &
STORAGE
Receiving: Food Carriers, Temperature Control,
Approved Suppliers

Storage: Ingredient, Allergen, Finished Product
and Chemical Storage

Transportation: Food Carriers, Temperature
Control
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PREREQUISITE PROGRAM:
TRANSPORTATION, RECEIVING & STORAGE
Transportation Receiving and Storage SOP

Monitoring Procedures: check each
shipment,

CAR: example

Allergen Program

Approved Suppliers Program
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PREREQUISITE PROGRAM:
EQUIPMENT
Equipment Design and Installation
Equipment Maintenance and Calibration
Equipment SOP
Temperature Monitoring Log
Thermometer Calibration


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PREREQUISITE PROGRAM:
PERSONNEL
Training: Hygiene and Technical
Hygiene and Health Requirements
Personnel SOP
Employee Sanitation SOP
Visitor Log Book

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PREREQUISITE PROGRAMS:
Sanitation & Pest Control
SANITATION
PEST CONTROL
SOP
PREOPS CHECKLIST
TRUCK CLEANING LOG

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PREREQUISITE PROGRAM:
RECALL
The Recall System
Complaints Log
Complaints Log SOP
Recall Template
Recall Notice
Allergen Alert Notice
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CRITICAL LIMITS
Is a value which separates acceptability
from unacceptability
Critical Limits must meet or exceed
government regulations
One or more critical limit must be met to
ensure a CCP is controlling the hazard
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CRITICAL LIMITS
Temperature / Time
pH
Aw (available water)
Preservatives
Available chlorine
Sensory observations
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SOURCES OF CRITICAL LIMITS
Regulatory Standards
Company Standards
Literature Surveys
Experimental Studies
Expert Advice
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CRITICAL LIMITS
Individual Product Profiles

Process Control Sheet
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PRODUCTION RECORDS
Using CIMS to record ingredients,
batch processing and finished
product information
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IMPORTANCE OF VERIFICATION
Ensures that all major processing steps
have been identified

Validates the assumptions made regarding
the movement of employees and product

Works towards continual improvement of
the GMP system
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IMPORTANCE OF VERIFICATION
Internal Audit

Internal Audit Template

Label Review