1. 1. A Briefing by Richard Bradford-Knox of RBK Consultants E Mail: richard@rbkconsultants.co.uk www.rbkconsultants.co.uk Food Safety Management Good Hygiene Practice & HACCP RBK Consultants
2. 2. What is the purpose of this E Book Presentation ? HACCP Hazard Analysis Critical Control Point is perceived and portrayed by some as a must have but complicated food safety management system that will solve all your food hygiene problems. Others see it as an unnecessary chore . It is not complicated , it is a legal requirement but when properly implemented its benefits outweigh the effort of implementation as a very useful tool in achieving the goal of safe food production. This presentation sets out to dispel some of the myths and explain in straight forward terms what it is ,the principles that drive it, and help you understand what is required to implement an effective Food Safety Management System (FSM) with HACCP as one of its attributes. RBK Consultants
3. 3. What is HACCP? The first thing to understand is that it is not a stand alone system. It is a Food Safety Management System that requires 2 elements .Firstly Good Hygiene Practice aka as prerequisites to HACCP which consist of all the hygiene practices that the food industry have been practising for many years and secondly HACCP itself which focuses on critical or key steps of food processing and production to ensure that food is produced as safely as possible for consumers. RBK Consultants
4. 4. What do we mean by a Food Safety Management System GHP & HACCP? A Food Safety Management System is an organised and defined way of managing food hygiene and keeping food safe for consumption. It is a combination of GHP Good Hygiene Practice . (AKA Good Manufacturing Practice and also known as Prerequisites to HACCP. HACCP is built on a foundation of GHP and is not a stand alone system. RBK Consultants
5. 5. GOOD HYGIENE PRACTICE OR PREREQUISITES Why? GHP/ Prerequisites are necessary to create or build a safe environment to produce safe food. Without this safe environment our food will vulnerable to contamination and the HACCP controls could be rendered useless. RBK Consultants
6. 6. RBK Consultants So What is needed to Create this Safe Environment ? GHP / Pre-Requisites are all of the practices and procedures that have to be in place or should have been in place to produce safe food long before HACCP was introduced. They consist of the following. Properly designed Facilities and layout Segregation between Raw & Cooked Products Process or Production Control Suitable Equipment Regular Maintenance of Equipment and Facilities Cleaning Sanitation and disinfection procedures Safe storage and disposal of Waste Food Hygiene & HACCP Training for all staff Personal Hygiene Pest Control Traceability of Ingredients
7. 7. GHP /Prerequisites It is not our intention to go into more detail about each aspect of GHP / Prerequisites. They are addressed it general Food Hygiene training programs and other presentations which you can also obtain from our web site and of course from other training organisations like Highfield or CIEH. RBK Consultants
8. 8. The Aim and Objectives of a Food Safety Management System or Program Aim :-To produce food that is fit for human consumption by: Identifying all hazards Controlling, reducing or eliminating them. Do so in the most efficient and economical way Being able to show or demonstrate that it is done. RBK Consultants
9. 9. Who & What do we need ? A team of people with a responsible attitude who are trained in food hygiene and food safety, are knowledgeable about their product(s) and how they are produced. Treat Food Safety as a Priority not as a burden Well planned documented policies and procedures A system that can be integrated with and are part of other day to day operations and management systems. E.g. Production and Quality control RBK Consultants
10. 10. HACCP IS A FARM TO FORK SYSTEM THE SYSTEM STARTS WHEN FOOD IS HARVESTED AND ENDS WHEN FOOD IS CONSUMED THAT IS THE BEGINNING AND END OF THE FOOD CHAIN EACH ORGANISATION OR STEP IN THE FOOD CHAIN MUST HAVE ITS OWN FOOD SAFETY MANAGEMENT SYSTEM WHICH LINKS TO THE NEXT ONE . RBK Consultants
11. 11. RBK Consultants It is important to understand the difference between Hazard & Risk Hazard :- Anything that can cause harm or lead to causing harm to Human Beings. Food itself can be and is regarded as a hazard but only if it is contaminated with hazardous substances or objects. These can be:- Biological Chemical Physical Allergens.
12. 12. RISK The likelihood, probability or risk of a hazard being the cause of harm and certain groups of people are more at risk than others. i.e. Children, Elderly people, sick people with a weak immune system Certain foods are more vulnerable to contamination than others and therefore considered to present a higher risk than others. E.g. Ready to Eat Foods, Foods High in protein and food containing moisture or water. RBK Consultants
13. 13. Hazard & Risk Analysis We class food as High, Medium or Low Risk. Note Low Risk does not mean NO Risk. In performing Hazard Analysis as a starting point we assume that there are hazards present in all food and the processes used to produce it. We also know that some foods are considered to present a higher risk than others and certain pathogens present a greater threat to human health than others. Unlike Health & Safety Risk Analysis it is not necessary to quantitatively assess the level of risk it presents . Just that there is a hazard and we must control or eliminate it. In identifying what hazards they present we can then formulate the best and most effective controls HACCP or GHP to reduce the risk of its potential to cause harm. RBK Consultants
14. 14. RBK Consultants What is a Control? A Control is the way we prevent food becoming a hazard. This can be by cooking, adjusting the pH, atmospheric packing, chilling , freezing, drying , reducing moisture levels and others.
15. 15. What is a Critical Control Point? A point at any stage in the process that actions are required to control or improve the safety of the product. There are many Control Points but not all of them are considered Critical in HACCP terms. Many are controlled or eliminated by Good Hygiene Practice and the Prerequisites we listed earlier. RBK Consultants
16. 16. RBK Consultants Critical Control Point Definition in Context of HACCP A Control Point is considered Critical when :- There is a Hazard to be controlled and it cannot be controlled at any other point in the Process. If not controlled could cause harm to humans.
17. 17. What do we mean by Critical The use of the term Critical in HACCP could be regarded as misleading. It implies that process steps procedures or actions not meeting the HACCP criteria for a CCP are not Critical. For example prerequisites such as lack of training, absence of hand washing or cross contamination can and have led to serious outbreaks of food borne disease. Therefore they can be regarded as equally Critical to the safety of food. RBK Consultants
18. 18. Another Example of Something That is Critical but not HACCPTraceability Not regarded as a HACCP CCP. Probably because the traceability or identification of ingredients has to be followed, at every step but not easy to set a critical Limit other than by its absence. Nevertheless a Critical and legal requirement. Think of Horsegate! Failure , deliberate or not ,to trace meat supplies and identify sources contributed horsemeat ending up in beef dishes. Food Businesses must be able to trace all ingredients/raw materials throughout the supply chain from source to consumer or end user and back to source. Includes cold stores, other temporary storage and distribution. RBK Consultants
19. 19. RBK Consultants HACCP is Based on 7 PRINCIPLES Conduct Hazard Analysis Determine CCPs Establish Critical Limits Establish Monitoring System Establish Corrective Actions Establish Verification Procedures Establish Documentation
20. 20. RBK Consultants PRINCIPLE 1 Conduct a hazard analysis Prepare a flow diagram of the steps in the process, identify and list the hazards and specify the control measures
21. 21. RBK Consultants Hazard Analysis Analysis of hazards associated with each product Evaluation of procedures concerned with production, distribution, and raw materials List the type of hazard (biological, chemical or physical) at each step. Devise appropriate preventive action or control to eliminate or keep the hazard under control.
22. 22. How do we decide what controls are appropriate ? All controls and Critical Limits must be based on sound scientific evidence and advice from a recognised authority. This must be obtained from a qualified source. For example: Local- EHOs and National Government- The FSA, DEFRA, World Health Organisation, Trade Associations, academically and professionally qualified auditors and consultants. E.g. IFST , SALSA, BRC ,RSPH or CIEH registered RBK Consultants
23. 23. Typical Control Processes and Preservation Techniques Temperature & Time Cooking , Freezing, Chilling Drying or Dehydrating Ph Levels Sugar and Salt levels Atmospheric Packing aka Gas flushing Sensory Observations Metal and X-ray Detection RBK Consultants
24. 24. Example Flow Chart Note that ingredients are listed at the top of the chart and are shown where they enter the process. Each step in the process is numbered and these will match those in the Control Table. It is important to check that every step is identified and shown including re-work . RBK Consultants
25. 25. RBK Consultants Flour Minced Meat- Chicken, Lamb or Beef Vegetable Oil - HACCP Flow Chart Meat Dumplings Prepared Vegetables Water Spices and Seasonings 3. Mix & Make dough 4. Cut & roll Pastry 1. CCP 1. Goods Received Chilled 1. Goods Received Ambient 1. Goods Received Ambient 1. Goods Received Ambient 3 a. Mix Dumpling Filling 5. Shape and Fill 6. Tray 7. Freeze