FOOD SAFETY

The new scheme FSSC 22000 is specific to food manufacturers, while ISO 22000 can apply to manufacturers as well as any other type of organization in the food supply chain.
PAS 220-2008 basically outlines the basic hygiene infrastructure and environment requirements to ensure users of ISO22000 comply with what GSFI embodies. Matter of fact, the dynamic nature of a Food Establishment requires a dynamic solution and approach.
More details can be from

http://www.dnv.com/binaries/FSSC%2022000%20presentation_tcm4-349388.pdf

The food safety team will create and implement a Hazard Analysis and Critical Control Point plan (HACCP Plan) for each product or process. The HACCP plan starts with some preliminary steps such as identifying product characteristics, describing
intended use, preparing flow diagrams and describing process steps.

The team uses this information to identify hazards that can be expected to occur, determine acceptable levels of the hazard and select control measures. The team identifies the control point where the hazard can be controlled, and the specific step that needs to be taken to successfully control the hazard. The plan for
controlling the hazard must be documented and include the hazard to be controlled, the control measure, critical limits, how the control point will be monitored, corrections and corrective actions to be taken if limits are exceeded, responsibilities and authorities and required records.

The food safety team will also establish a plan for verification activities to ensure that the PRPs are implemented, inputs to hazard analysis are updated, the operational PRPs and HACCP plan are implemented and effective and the hazard levels are within limits. Verification activities make sure the HACCP system is in
compliance.

A system of traceability of product must be in place. Make sure that you can perform an effective recall if necessary. You must also be able to control any nonconforming product. Document your process to control affected product when critical control limits are exceeded. Include taking action to identify and eliminate the cause of nonconformity and prevent nonconforming product from entering the food chain.

Once the system is implemented you will be verifying that it is working on an ongoing basis. The verification will include internal audits by your own audit team and food safety team evaluation of the verification activities.

If you are already in the food industry, and providing a safe food product or service, you most likely have many of these practices in place even though they may not be formally documented. Adding the effectiveness of a documented food safety management system will provide your company not only the benefits of recognition of having a management system in place, but also the benefits of quality management and the security of producing safe product for your customers. Take your system to the next level with ISO 22000.

Steps are

1- Learn about 22000 Food Safety Management Systems
2- Compare your current system to the requirements.
3- Plan your project
4- Design and document your system
5- Train employees and an internal audit team
6- Have your registration audit

The monitoring that takes place at the critical control points is essential to the effectiveness of the HACCP program. The monitoring program will be made up of physical measurement or observations that can be done in a timely manner, to provide the information in a time frame that allows you to take action and control product if an out of control situation occurs.

The food safety team must identify appropriate monitoring for each critical control point. The monitoring must be specifically designed to monitor the specific hazard that is being controlled at that point. The method should give you early warning if a process is losing control, and let you know if a critical limit has been exceeded.

Design a data analysis plan that will give you the information you need about the process at the critical control point. Identify the appropriate measuring equipment, responsibilities for measuring or observation as well as training and qualifications of those responsible.

The plan must address how data will be recorded, reviewed and analyzed. If continuous monitoring is not in place, for example sampling of raw material, then the appropriate statistics will be needed to determine the frequency of measurement.

The location of the monitoring is also a key element. It must take place exactly where the hazard is being controlled.

Corrective action is taken whenever a critical control limit is exceeded. Each critical control point identified in the HACCP plan will also need a specific planned corrective action to be taken if the control limit is exceeded.

The action or actions taken have two purposes, to control any nonconforming product
resulting from the loss of control, and to identify the cause, eliminate it and prevent the situation from reoccurring.

By identifying the corrective action before an out of control situation occurs, you are prepared to take action quickly if and when it does occur. Identification of the action should also include responsibilities and authorities for taking action.

The product that was processed or manufactured when the process was operating outside control limits must be immediately identified and controlled to prevent its continuing through production. The HACCP plan will also assign responsibility for determining product disposition. Will the product be disposed of, reworked, regraded?
The disposition must be recorded.

The cause of the loss of control must then be identified. This may require a root cause analysis and investigation to identify underlying causes. Once the cause is identified, corrective action is required to eliminate the cause, and prevent it from happening again. This may include changing procedures or equipment, evaluating
and improving training or many other possible actions.

Section 4: SQF 2000 System Requirements:

4.3 Specification and Product Development
4.3.1 Product Development and Realization
4.3.2 Raw materials
4.3.3 Packaging
4.3.4 Contract Service Providers
4.3.5 Contract Manufacturers
4.3.6 Finished product
4.4 Attaining Food Safety
4.4.1 Food Legislation (Regulation)
4.4.2 Food Safety Fundamentals
4.4.3 Food Safety Plan
4.4.4 Food Quality Plan
4.4.5 Incoming Goods and Services
4.4.6 Corrective and Preventative Action
4.4.7 Non-conforming Product or Equipment
4.4.8 Product Rework
4.4.9 Product Release
4.4.10 Stock Rotation

The SQF 2000 Code has 13 Sections while main sections are

Section 1 Scope
Section 2 References
Section 3 Definitions
Section 4 SQF 2000 System Requirements
Section 5 Food Safety Fundamentals – Building and Equipment Design and Construction
Section 6 Food Safety Fundamentals – Prerequisite Programmes

Internal Audits leads to great improvement in the effectiveness and efficiency of the ISO system. Some guidelines to improve internal audits in organization/system.

• Make sure the authority of the audit team is established. This will increase the cooperation from auditees. Auditor training is necessary for success of system
  

• Decide scope and frequency of the audit.Prepare a yearly audit schedule and distribute.

• Develop an audit plan. Decide what other audit resources are needed - checklists, other auditors?

• Determine the purpose of the audit - is it an overview of the area being audited or is it to concentrate on a specific system within the area?

• Determine the purpose of the audit - is it to comply with government regulations, quality standards, internal procedures and system?

• Hold a meeting with the auditors to discuss the plan, purpose, and scope of the audit.

• Read the documents you will be auditing against. Know what they say. Develop questions to ask the auditees.

• Conduct an opening meeting with the auditees.

The SQF Codes: Three certification levels

Level 1
Food Safety Fundamentals. Indicates that prerequisite programs and fundamental food safety controls have been implemented to provide a sound foundation for the further development of the Organization’s management system.

Level 2
Food Safety HACCP Plans Incorporates all Level 1 system requirements and indicates that a food safety risk analysis of the product and its associated process has been completed to identify the hazards and the actions taken to eliminate, prevent or reduce their occurrence.

Level 3
Comprehensive Food Safety and Quality Management Systems Development. Incorporates all Level 1 and Level 2 system requirements and indicates that a food quality risk assessment of the product and its associated process have been completed, that the actions taken to prevent the incidence of poor quality and the remaining quality management systems procedures have been implemented.

* The Global Food Safety Initiative (GFSI) is coordinated by CIES - The Food Business Forum, launched May 2000.

PAS 220 is made up of the core requirements specified in ISO 22000 under sub clause 7.2.3, but with the additional requirements that have been considered important and relevant to the food manufacturing process. A brief summary is given below; however, further details are available at www.food.lrqa.com

1. The scope - applicable to all food manufacturing organizations.
2. Normative reference identifies the reference materials.
3. 19 terms and definitions to compliment the 82 in ISO 9001 and 17 in ISO 22000
4. The construction and layout of buildings for contamination control and prevention.
5. The layout of premises and workspace
6. Utilities - air, water, energy covering water quality, approved chemicals, ventilation etc.
7. Waste disposal - containers for waste or hazardous substances, waste management, drains and drainage.
8. Equipment suitability, cleaning and maintenance specifies that equipment should be made of material inert to the food being processed.
9. The management of purchased materials covers the selection of suppliers and the handling of received goods.
10. Physical, microbiological and allergen contamination is covered in the section dealing with measures for prevention of cross contamination.
11. Cleaning and sanitizing
12. Pest Control including pest control programs, preventing access, harbourage and infestations, monitoring and detection, and eradication.
13. Personnel hygiene and employee facilities - locker facilities, toilets, staff canteens and designated areas. It also addresses work wear, protective clothing, health status, illness and injury, employee cleanliness and behavior in a processing and warehousing environment.
14. Rework is an integral part of the process with regard to traceability and allergen control. Repackage is also considered as rework material.
15. Product recall procedures include the requirement for a key contact list and traceability of product produced under similar conditions as the recall product.
16. Warehousing - cleanliness, dryness, ventilation, dust and temperature control, separate areas for storage of chemicals, and designated areas for non-conforming materials. Warehouse practices such as FIFO/FEFO, vehicle upkeep and maintenance.
17. Product information/consumer awareness - how information is presented to the consumer to facilitate informed decisions.
18. Food defense, biovigilance and bioterrorism - protective measures to guard against acts of terrorism, tampering, sabotage and access control.