GOOD

MANUFACTURIN
G PRACTICES

GOOD MANUFACTURING
PRACTICES
Training about our Food Safety Plan

HACCP ACRONYM

H
A
C
C
P

GOOD
MANUFACTURIN
G PRACTICES

azzard
nalysis
ritical
ontrol
oint
2

HISTORY OF THE HACCP

SYSTEM

GOOD
MANUFACTURIN
G PRACTICES

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
3

WHAT IS HACCP?

GOOD
MANUFACTURIN
G PRACTICES

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)

KEY CONCEPTS OF A
HACCP PLAN

GOOD
MANUFACTURIN
G PRACTICES

Good Manufacturing Practices

(GMPs)
Standard Operating Procedures
(SOPs)

SOPs ALLOW YOU TO:

GOOD
MANUFACTURIN
G PRACTICES

1. SAY what you do

2. DO what you say
3. PROVE it

WHAT ARE CCPs

(Critical Control Points)?

GOOD
MANUFACTURIN
G PRACTICES

A CCP is a key step where hazards

can be prevented, eliminated or
reduced to an acceptable level.

THE SUCCESS OF HACCP

AND THE SEVEN
PRINCIPLES

GOOD
MANUFACTURIN
G PRACTICES

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
8

PREREQUISITE
PROGRAMS

GOOD
MANUFACTURIN
G PRACTICES

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

GOOD MANUFACTURING
PRACTICES (GMPs)

GOOD
MANUFACTURIN
G PRACTICES

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)

10

GMPs ARE:

GOOD
MANUFACTURIN
G PRACTICES

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

11

STANDARD OPERATING
PROCEDURES (SOPs)

GOOD
MANUFACTURIN
G PRACTICES

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
12

CORRECTIVE ACTION
REQUEST
A CAR must be
completed for each
deviation from the
SOP
CAR Form
CAR Instructions

GOOD
MANUFACTURIN
G PRACTICES

State deviation
Use objective Evidence
Develop an action plan
to prevent deviation
reoccurrence
Set a deadline
Verify that the action
plan has been effective

13

PREREQUISITE PROGRAM:
PREMISES

GOOD
MANUFACTURIN
G PRACTICES

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

14

PREREQUISITE PROGRAM:
PREMISES

GOOD
MANUFACTURIN
G PRACTICES

Premises SOP
Monitoring Procedure: part of
internal audit procedures

15

PREREQUISITE PROGRAM:

TRANSPORTATION, RECEIVING &

STORAGE

GOOD
MANUFACTURIN
G PRACTICES

Receiving: Food Carriers, Temperature

Control, Approved Suppliers

Storage: Ingredient, Allergen, Finished

Product and Chemical Storage

Transportation: Food Carriers,

Temperature Control

16

PREREQUISITE PROGRAM:
TRANSPORTATION, RECEIVING &
STORAGE

GOOD
MANUFACTURIN
G PRACTICES

Transportation Receiving and Storage SOP

Monitoring Procedures: check each
shipment,
CAR: example
Allergen Program
Approved Suppliers Program
17

PREREQUISITE PROGRAM:
EQUIPMENT

GOOD
MANUFACTURIN
G PRACTICES

Equipment Design and Installation

Equipment Maintenance and Calibration
Equipment SOP
Temperature Monitoring Log
Thermometer Calibration

18

PREREQUISITE PROGRAM:
PERSONNEL

GOOD
MANUFACTURIN
G PRACTICES

Training: Hygiene and Technical

Hygiene and Health Requirements
Personnel SOP
Employee Sanitation SOP
Visitor Log Book
19

PREREQUISITE
PROGRAMS: Sanitation &
Pest Control

GOOD
MANUFACTURIN
G PRACTICES

SANITATION
PEST CONTROL
SOP
PREOPS CHECKLIST
TRUCK CLEANING LOG

20

PREREQUISITE PROGRAM:
RECALL

GOOD
MANUFACTURIN
G PRACTICES

The Recall System

Complaints Log
Complaints Log SOP
Recall Template
Recall Notice
Allergen Alert Notice

21

CRITICAL LIMITS

GOOD
MANUFACTURIN
G PRACTICES

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
22

CRITICAL LIMITS

GOOD
MANUFACTURIN
G PRACTICES

Temperature / Time
pH
Aw (available water)
Preservatives
Available chlorine
Sensory observations
23

SOURCES OF CRITICAL
LIMITS

GOOD
MANUFACTURIN
G PRACTICES

Regulatory Standards
Company Standards
Literature Surveys
Experimental Studies
Expert Advice
24

CRITICAL LIMITS

GOOD
MANUFACTURIN
G PRACTICES

Individual Product Profiles

Process Control Sheet

25

PRODUCTION RECORDS

GOOD
MANUFACTURIN
G PRACTICES

Using CIMS to record ingredients,

batch processing and finished
product information

26

IMPORTANCE OF
VERIFICATION

GOOD
MANUFACTURIN
G PRACTICES

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

27

IMPORTANCE OF
VERIFICATION

GOOD
MANUFACTURIN
G PRACTICES

Internal Audit
Internal Audit Template
Label Review

28