GOOD

MANUFACTURIN
G PRACTICES

GOOD MANUFACTURING
PRACTICES
Training about our Food Safety Plan
HACCP ACRONYM
GOOD
MANUFACTURIN
G PRACTICES

H azzard
A nalysis
C ritical
C ontrol
P oint

Good Management Practices Dec-07 2

HISTORY OF THE HACCP GOOD
MANUFACTURIN

SYSTEM
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
Good Management Practices Dec-07 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) 4
Good Management Practices Dec-07
KEY CONCEPTS OF A GOOD
MANUFACTURIN

HACCP PLAN
G PRACTICES

Good Manufacturing Practices

(GMPs)

Standard Operating Procedures

(SOPs)

Good Management Practices Dec-07 5

SOPs ALLOW YOU TO:
GOOD
MANUFACTURIN
G PRACTICES

1. SAY what you do

2. DO what you say

3. PROVE it

Good Management Practices Dec-07 6

WHAT ARE CCPs GOOD
MANUFACTURIN
G PRACTICES
(Critical Control Points)?

A CCP is a key step where hazards

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

Good Management Practices Dec-07 7

THE SUCCESS OF HACCP GOOD
MANUFACTURIN

AND THE SEVEN G PRACTICES

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

Good Management Practices Dec-07 8

PREREQUISITE GOOD
MANUFACTURIN

PROGRAMS
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 Management Practices Dec-07 9

GOOD MANUFACTURING GOOD
MANUFACTURIN

PRACTICES (GMPs)
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)

Good Management Practices Dec-07 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

Good Management Practices Dec-07 11

STANDARD OPERATING GOOD
MANUFACTURIN

PROCEDURES (SOPs)
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

Good Management Practices Dec-07 12

CORRECTIVE ACTION GOOD
MANUFACTURIN

REQUEST
G PRACTICES

A CAR must be State deviation

completed for each
deviation from the
SOP
CAR Form
CAR Instructions
Use objective Evidence
Develop an action plan
to prevent deviation
reoccurrence
Set a deadline
Verify that the action
plan has been effective

Good Management Practices Dec-07 13

PREREQUISITE PROGRAM: GOOD
MANUFACTURIN

PREMISES
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

Good Management Practices Dec-07 14

PREREQUISITE PROGRAM: GOOD
MANUFACTURIN

PREMISES
G PRACTICES

Premises SOP

Monitoring Procedure: part of

internal audit procedures

Good Management Practices Dec-07 15

PREREQUISITE PROGRAM: GOOD
MANUFACTURIN
TRANSPORTATION, RECEIVING & G PRACTICES

STORAGE

Receiving: Food Carriers, Temperature

Control, Approved Suppliers

Storage: Ingredient, Allergen, Finished

Product and Chemical Storage

Transportation: Food Carriers,

Temperature Control

Good Management Practices Dec-07 16

PREREQUISITE PROGRAM: GOOD
MANUFACTURIN
TRANSPORTATION, RECEIVING & G PRACTICES

STORAGE

Transportation Receiving and Storage SOP

Monitoring Procedures: check each

shipment,

CAR: example

Allergen Program

Approved Suppliers Program

Good Management Practices Dec-07 17

PREREQUISITE PROGRAM: GOOD
MANUFACTURIN

EQUIPMENT
G PRACTICES

Equipment Design and Installation

Equipment Maintenance and Calibration

Equipment SOP

Temperature Monitoring Log

Thermometer Calibration

Good Management Practices Dec-07 18

PREREQUISITE PROGRAM: GOOD
MANUFACTURIN

PERSONNEL
G PRACTICES

Training: Hygiene and Technical

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

Good Management Practices Dec-07 19

PREREQUISITE GOOD
MANUFACTURIN

PROGRAMS: Sanitation & G PRACTICES

Pest Control
SANITATION
PEST CONTROL
SOP
PREOPS CHECKLIST
TRUCK CLEANING LOG

Good Management Practices Dec-07 20

PREREQUISITE PROGRAM: GOOD
MANUFACTURIN

RECALL
G PRACTICES

The Recall System

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

Good Management Practices Dec-07 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

Good Management Practices Dec-07 22

CRITICAL LIMITS
GOOD
MANUFACTURIN
G PRACTICES

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

Good Management Practices Dec-07 23

SOURCES OF CRITICAL GOOD
MANUFACTURIN

LIMITS
G PRACTICES

Regulatory Standards

Company Standards

Literature Surveys

Experimental Studies

Expert Advice

Good Management Practices Dec-07 24

CRITICAL LIMITS
GOOD
MANUFACTURIN
G PRACTICES

Individual Product Profiles

Process Control Sheet

Good Management Practices Dec-07 25

PRODUCTION RECORDS
GOOD
MANUFACTURIN
G PRACTICES

Using CIMS to record ingredients,

batch processing and finished
product information

Good Management Practices Dec-07 26

IMPORTANCE OF GOOD
MANUFACTURIN

VERIFICATION
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

Good Management Practices Dec-07 27

IMPORTANCE OF GOOD
MANUFACTURIN

VERIFICATION
G PRACTICES

Internal Audit

Internal Audit Template

Label Review

Good Management Practices Dec-07 28