4.1.2.3.food.safety.quality.diagram.training

?
Who How

What
Whom

LOSURDO FOODS, INC
TRAINING: SQF 2000 SYSTEM (SAFE QUALITY FOOD)
 What is SQF; Western Australia late 1990‟s
 Why do retailers turn to a System like SQF
 Why are some retailers not requiring SQF Certification (YET)
 Why us
 How much do we risk if we don‟t?
 SQF is as easy as 2 phrases;
 Say what “you” do
 Do what “you” say
 OR
 The methods to ensure our products are safe quality foods are: ___________________
ReceivingStartup
Ball Line Inline
and the responsibilities' belongreceivers
TankLine ______________ and SHALL be documented and
Ball to: Filters
Check
implemented on :___________________________, and verified by:____________
4.1.1.ii.1.Milk.Receiving.Log
4.1.1.ii.1.Packing.Line.Check
Lead Jeff DeFrance .
Jeff DeFrance

HOW TO INTERPRET SQF REQUIREMENTS

 What must happen
 How do we make it happen & How do we prove it
happened; what documentation is required to instruct how
and what is needed to document and prove it!
 Who is required to make it happen

 Whom needs to know these things!

 4.1.1 Management Policy
 The owner or most senior person shall define the Supplier‟s
commitment to food safety, quality and continuous improvement as
well as make resources available to achieve these objectives in a
Policy Statement; which is relevant to the Supplier‟s goals and
customer requirements. The owner or most senior person must
sign the policy statement, have it documented in the Policy
Manual, and ensure it is communicated to all employees and
staff.

GLOBAL FOOD SAFETY INITIATIVE (GFSI)

 Welcome to the Global Food Safety Initiative
 The Global Food Safety Initiative (GFSI) is a collaboration between
some of the world's leading food safety experts from
retailer, manufacturer and food service companies, as well as service
providers associated with the food supply chain. It is coordinated by
The Consumer Goods Forum, the only independent global network for
consumer goods retailers and manufacturers worldwide. It serves the
CEOs and senior management of nearly 400 members, in over 150
countries.

GLOBAL FOOD SAFETY INITIATIVE (GFSI)

 Why did the Global Food Safety Initiative begin?
 In May 2000, following a number of food safety scares, a group of
international retailer CEOs identified the need to enhance food
safety, ensure consumer protection and to strengthen consumer
confidence. They launched the Global Food Safety Initiative which sets
requirements for food safety schemes through a benchmarking
process in order to improve cost efficiency throughout the food supply
chain.
 Members include 70% of the World‟s food retail revenue and has 9000
companies SQF certified worldwide

CONSULTING MAJOR US FIRMS ADOPTING SQF
Already requiring SQF
Certification
WalMart Under review and consideration
•US Foodservice at many other firms:
•Stop & Shop –Kroger
•Giant –Wegman‟s
•Price Chopper –Harris Teeter
•Lund‟s & Byerly‟s –Costco
•HEB –Sysco
•Food Lion –Yum Brands
•Hannaford Bros. –McDonalds

THREE LEVELS OF IMPLEMENTATION

INTERGRATED QUALITY LEVEL 3 FOOD QUALITY PLAN
MANAGEMENT
HACCP & FOOD SAFETY
FOOD SAFETY MANAGEMENT LEVEL 2 PLANS

FOOD SAFETY FUNDEMENTALS LEVEL 1 PREREQUISITE PROGRAMS

 What does SQF mean by “you”; you might ask
yourself, why is this all on me / us?
 Remember Say what “you” do; of the three statements below, who
would be the “you”
 Losurdo Foods, Inc will provide annual GMP refresher training.
 Losurdo Foods, Inc will maintain needed inventories of cleaning utensils
needed to maintain the facility is a constant state of sanitation to avoid
product contamination.
 Losurdo Foods, Inc will provide PPE and maintain inventories needed to
provide employees, contractors, and visitors the ability to protect
themselves from hazards encountered at its facilities.
 You = Losurdo Foods, Inc

FOREIGN MATERIAL CONTROL: METAL DETECTOR SOP
 Purpose: What
 To minimize the possibility of metal from processing equipment getting into
consumer product. This operation is done through the use of metal detection
devices used in the product packaging lines. The procedure covers the analyzing
of our products for foreign material prior to shipment.
 Method: How
 Performance of the metal detectors are determined by the size of the machine itself
and its set up, as well as size, shape, density, temperature and the composition of
the product. To ensure that the metal detectors are in proper working condition they
are to be calibrated for each product. The product format is entered into the
machine and checked throughout that product run. The test calibration pieces
ensure that calibration has been retained. Responsibilities: Who

FOREIGN MATERIAL CONTROL: METAL DETECTOR SOP

 Responsibilities: Who
 Itis the responsibility of the packing personnel to test the performance
of the metal detectors as identified in the above the procedures. They
are to notify Management in the event that the detector is not
performing the way it should. It is the responsibility of packing
personnel to perform the Daily Preventive maintenance on the metal
detectors.
 Responsibilities: Whom
 What facility personnel must be trained and follow this SOP?

JUST HACCP VERSES JUST PRE-REQUISITE PROGRAMS
 Why do we need both?

 In its 1997 document titled "Hazard Analysis and
Critical Control Point Principles and Application," the
National Advisory Committee on Microbiological Criteria
for Foods (NACMCF) states, "The production of safe
food products requires that the HACCP system be built
upon a solid foundation of prerequisite
programs...Prerequisite programs provide the basic
environment and operating conditions that are
necessary for the production of safe, wholesome food.“

JUST HACCP VERSES JUST PRE-REQUISITE PROGRAMS
 The success of the HACCP system depends on
prerequisite programs that are both active and
effective. Many potential hazards can be eliminated or
reduced to a "non-hazardous" state through well-
defined and effective prerequisite programs.

JUST HACCP VERSES JUST PRE-REQUISITE PROGRAMS CONT.
 NO EASY WAY OUT
 So, why bother with the prerequisite program if HACCP can do
the same thing? Creating critical control points (CCPs) and
managing them through the HACCP plan is not always a viable
option. CCPs have significant requirements. introducing a CCP
places demands on the system, which may not always be
practical. Deviation is critical and must be
addressed, documented and supported by records to
demonstrate actions taken. A pre-determined corrective action
must define an immediate action to divert the product and to
ensure that violated product is not released for consumption.

JUST HACCP VERSES JUST PRE-REQUISITE PROGRAMS CONT.
 Whenever possible, the best solution is to define and manage as many
potential hazards as possible in a prerequisite program.
 The focus of prerequisite programs do differ from the overall
HACCP focus. Generally, a prerequisite program applies across
product lines that are managed system or process wide. The
HACCP plan focus is product specific. Every deviation in a
prerequisite program's requirement will not necessarily result in
a food safety hazard, yet the effectiveness of the overall
program may affect the HACCP system (product safety).

SQF 2000 SYSTEM
 Section 4 –SQF System Requirements
 Section 5 –Food Safety Fundamentals –Building
and Equipment Design and Construction
 Section 6 –Food Safety Fundamentals –Pre-
requisite Programs

SQF 2000 SECTION 4 –SYSTEM REQUIREMENTS

 Section 4.1 of SQF –Commitment
 4.1.1 Management Policy
 Policy
statement with commitment to quality and safety must be written
and signed by Senior management; must be displayed for all
employees
 4.1.2 Management Responsibility
 Organizationalstructure in place with designated responsibility for food
safety (resources, training, job descriptions


 4.1.3 Food Safety and Quality Management System
 Policy manual, food safety manual, and quality manual in place
 4.1.4 Management Review
A system is in place for management to review SQF system annually


 4.1.5 Compliant Management
A system for recording, reviewing, and responding to customer
complaints
 4.1.6 Business Continuity Planning
A crisis management plan is in place


 Section 4.2 of SQF –Document Control and Records
 4.2.1 Document Control
 Documents are maintained, accessible, and current. Maintained by
designated person.
 4.2.2 Records
 Recordsare securely maintained. Procedures detail person
responsible for completion and person for verification as well as how to
be completed.


 Section 4.3 of SQF –Specifications and Product
Development
 4.3.1 Product Development and Realization
 Procedures for conducting R&D, approving, and validating.
 4.3.2 and 4.3.3 Raw Materials and Packaging
 Specificationsfor raw materials and packaging with list of suppliers,
supplier approval, and procedures for receipt of materials verifying that
they are from approved supplier.


Development
 4.3.4 Contract Services
 Procedures and documentation for any contract services
 4.3.5 Contract Manufacturers
 Willinclude suppliers of Product contact, raw materials, processing
aids, and / or ingredients to your facility. Procedures for approval and
evaluating supplier.


Development
 4.3.6 Finished Product
 Finishedproduct specifications with review. Product labels established.
All comply with government regulations and customer requirements.


 Section 4.4 of SQF –Attaining Food Safety
 4.4.1 Food Legislation
 Aware of applicable food regulations and that facility complies with
federal state and local regulations including having appropriate
licenses
 4.4.2 Food Safety Fundamentals
 Policies
address practices to address facilities, equipment, and
prerequisite programs


 4.4.3 Food Safety Plan
 HACCP in place, maintained, and validated
 4.4.4 Incoming Goods and Services
 Approved supplier, raw material inspection, and monitoring or raw
material suppliers. Also, emergency receipt of materials


 4.4.6 Corrective and Preventive Action
 Proceduresfor corrective action with record keeping and preventive
measures taken
 4.4.7 Non-Conforming Product or Equipment
 Who is responsible for non-conforming product and how is it controlled


 4.4.8 Product Rework
 Who is responsible for reworking product and how is it controlled
 4.4.9 Product Release
 Who is responsible for releasing product and how is it controlled
 4.4.10 Stock Rotation
A Stock rotation procedure is in place


 Section 4.5 of SQF –Verification
 4.5.1 Verification
 Verificationof pre-requisite programs, control steps with established
limits, and monitoring
 4.5.2 Validation
 Do programs ensure process meets intended limits


 4.5.3 Verification of Monitoring Activities
 Documentation of methods, responsibilities, and criteria for verifying
effectiveness of pre-requisite programs and HACCP
 4.5.4 Product Sampling, Inspection, and Analysis
 Procedures for testing and sampling written, responsibility
assigned, and records maintained


 4.5.5 Internal Audit
 Procedures and responsibility for internal audits
 4.5.6 SQF Verification Schedule
 Procedures, frequency, and responsibility for checking the
effectiveness of the SQF system


 Section 4.6 of SQF –Product Identification
 4.6.1 Product Identification
 Methods and responsibilities for identifying product during all stages of
production
 4.6.2 Product Trace
 System to complete „one forward, one back‟ traceability


 Section 4.6 of SQF –Product Identification
 4.6.3 Product Withdrawal and Recall
 Procedures
for recall including methods, responsibilities and
management procedures, must conduct mock recalls


 Section 4.7 of SQF –Food Defense (US Army)
 4.7.1 Food Defense
 Food defense protocol that outlines the methods, responsibilities, and
criteria for preventing intentional contamination (Prerequisite Program
#14)


 Section 4.6 of SQF –Identify Preserved Foods
 4.8.1 General requirements
 Methods for maintaining special attributes of the food and their raw
materials
 Allergens, organic, GMO, kosher

SQF 2000 SECTION 5 –FOOD SAFETY FUNDAMENTALS

 Section 5.0 of SQF
 5.1 Site Requirements and Approvals

 5.2 Food Handling Areas

 5.3 Water and Ice Supply

 5.4 Storage Facilities

 5.5 Separation of Functions (prevent cross contamination)
SEPARATING FUNCTIONS

 5.6 On-Site Laboratories

SQF 2000 SECTION 5 –FOOD SAFETY FUNDAMENTALS

 5.7 Staff Amenities (Restrooms, break rooms, etc)
 5.8 First Aid Facilities

 5.9 Waste Disposal

 5.10 Exterior

SQF 2000 SECTION 6 –PREREQUISITE PROGRAMS
O
B

 Section 6.0 of SQF S
E
R
 6.1 Personnel Practices V
A
T
 6.2 Personnel Processing Practices
PERFORMANCE
I
REVIEW
JOB
INTERVIEW O
 6.3 Training of Personnel ASSIGNMENTS
PROCESS N
S
RECORD KEEPING
 6.4 Calibration of Equipment

 6.5 Pest Control

 6.6 Maintenance of Equipment

 Section 6.0 of SQF
 6.7 Cleaning and Sanitizing
 6.8 Monitoring Water Micro and Quality
 6.9 Control of Physical Contaminants
 6.10 Supplier Approval
 6.11 Receiving, Storage, Transport and Delivery (ours)
 6.12 Waste Management
 6.13 Allergen Control


 Section 6.0 of SQF: LFI additions
 6.14 Food Defense (LFI Addition)

 6.15 Customer Complaints (LFI Addition)
D
 6.16 Traceability, Recall & Withdrawal (LFI Addition)

7
S Q
AFE
TY
UALI
F OODS

2 S
HACCP
PRINCIPLES
1.FD &
HAZARD ANALYSES
2.CRITICAL CONTROL
INTERACTIVE 000 ystem
POINTS
3.OP LIMITS & CRITICAL LIMITS PRE-EMPTIVE
4.MONITORING
5.CORRECTIVE ACTIONS
QUALITY
6.VALIDATING
VERIFING SYSTEM VERIFICATION
7.RECORD
KEEPING EMPLOYEE
ORGANIZATIONAL ENVOLVMEN
COMMITMENT T
SANITATION TEAMS
SELF
STANDARD INSPECTIONS
OPERATING &
SELF
CONTROL
PROCEDURES REGULATORY
COMPAN
STANDARD
INSPECTIONS
OPERATING
AUDITS
& 3RD
MECHANISM
Y PROCEDUR PARTY S
POLICIE ES AUDITS
PERSONN WATER CRITICAL
S
EL QUALITY EQUIPMENT
PRACTICE PROGRA CALIBRATION
S PERSONNE PREMISES S
M
TRAININGPROGRAM L EQUIPMENT PROGRAMCLEANING
EDUCATION PROCESSIN MAINTENAN SANITATION VALIDATION
AL G CE PROGRAM
PROGRAM
CUSTOMER
PRACTICES
RECEIVING
PROGRAM
PHYSICAL WASTE STANDAR
PROGRAM
COMPLAINT STORAGE CONTAMINAT CONTROL DS,
S TRANSPO ES PROGRA
PROGRAM RT CONTROL M SAFETY, &
TRACEABILI APPROVE PROGRAM ALLERG PROGRAM PEST FOOD STABILITY
TY D EN MANAGEMEN DEFENS
RECALL SUPPLIER CONTRO T E
PROGRAM PROGRA L PROGRAM PROGRA

16 – PREREQUISITE PROGRAMS
M PROGRA
M
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7
S Q
AFE
TY
UALI
F OODS

2 S
HACCP
PRINCIPLES
1.FD &
HAZARD ANALYSES
2.CRITICAL CONTROL
POINTS
4.MONITORING
QUALITY
6.VALIDATING
VERIFING SYSTEM VERIFICATION
7.RECORD
KEEPING EMPLOYEE
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SANITATION TEAMS
SELF
OPERATING &
SELF
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COMPAN
STANDARD
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AUDITS
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MECHANISM
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POLICIE ES AUDITS
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S
PRACTICE PROGRA CALIBRATION
S PERSONNE PREMISES S
M
TRAININGPROGRAM L EQUIPMENT PROGRAMCLEANING
EDUCATION PROCESSIN MAINTENAN SANITATION VALIDATION
AL G CE PROGRAM
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CUSTOMER
PRACTICES
RECEIVING
PROGRAM
PROGRAM
COMPLAINT STORAGE CONTAMINAT CONTROL DS, SAFET
S TRANSPO ES PROGRA
PROGRAM RT CONTROL M Y, &
TRACEABILI APPROVE PROGRAM ALLERG PROGRAM PEST FOOD STABILITY

M PROGRA
M
M

STANDARDS, SAFETY, & STABILITY
Product Identification, Traceability and Recall Programs The ability to
identify and trace raw materials through finished product is essential.
The product recall program should include mock recalls performed at
a defined frequency (i.e., semi-annually) and records confirming
acceptable results. Do not wait for a real situation to learn the
program is not effective.
Labeling (Application and Control) Product must be labeled
TRACEABIL
appropriately; labels must clearly identify the product and its
ITY
RECALL ingredients. Labels must be evaluated to ensure that they contain all
PROGRAM
required information and meet legal requirements for product
TRACEABILITY,should be performed to ensure
identification and content. Evaluation
REC
proper labels are ALL, WITHDRAWAL
applied to corresponding products. An ineffective
PROGRAM
label-management program could result in a serious food safety
issue.
.....A_EDAA_SQF6. SQF REQUIREMENTS FOR PRE-
REQUISITES6.16.TRACEABILITY.RECALL.PREREQUISITE.PROGRAM0_6.16.RECALL.WITHDRAWAL.PRO
CEDURE.OUTLINE.docx

CONTINUED

Introduction and aim of procedure has product safety, product
quality, quality, and service as its products and services. It aims to be
fair and transparent in its operations, in particular in the process of
managing complaints, CUSTOMER about a corrective action and
in order to bring
mutually agreeable solution for all parties.
CUSTOMER
COMPLAIN
COMPLAINTS
Complaints may be made by any external person or organization and
TS
PROGRAM
can be received by any PROGRAM member of Losurdo Foods‟ staff. The aim of
this procedure is to describe the process of receipt (who, what,
where, and why), logging (full description of the complaint detail
specifically product “Best By Code”, size, and product the type), and
(corrective actions) and resolution of all complaints
received.....A_EDAA_SQF6. SQF REQUIREMENTS FOR PRE-
REQUISITES6.15.CUSTOMER.COMPLAINTS.PREREQUISITE.PROGRAM6.15.CUSTOMER.COMPLAINTS.LOG.HEUVELTON.xlsx

STANDARDS, SAFETY, & STABILITY CONTINUED
Supplier Certification and On-going Evaluation Programs
Supplier assurance that specific criteria are met should be
an essential part of the HACCP plan. Many potential hazards
related to the raw ingredient supply may be controlled
through an effective supplier assurance program. Supplier
programs should include requirements for identifying and
qualifying suppliers, the means to monitor existing
APPROVE suppliers at defined frequencies, and handling any negative
D
SUPPLIER supplier issues. Keep in mind that if an assurance is made
PROGRAM
APPROVED
based on a COA (certificate of approval) or a COC
SUPPLIER process should also
(certificate of compliance) then the
PROGRAM
identify a means to spot check incoming items (testing, etc.)
at a defined frequency to verify the accuracy of the
supplier's results.
.....A_EDAA_SQF-AMSTERDAM6. SQF REQUIREMENTS FOR PRE-
REQUISITES6.10.SUPPLIER.APPROVAL.PREREQUISITE.PROGRAMMIZKAM WHITE VINEGAR 6.10.2.1.i.SUPPLIER.SPECIFICATION.docx

CONTINUED

Receiving, Storing and Controlling Raw Ingredients and Materials
Inspections performed on raw ingredients and materials must ensure
RECEIVING
that all defined requirements are in compliance for the specific item
RECEIVING
STORAGE
before its receipt and are especially critical for requirements related to
STORAGE
TRANSPOR
T PROGRAM TRANSPORT
food safety hazard. Procedure requirements should be well defined;
inspection and verification activities should be documented and
PROGRAM
maintained. Receiving inspection may link closely with supplier
approval and evaluation requirements. All items must be stored in a
manner that assures quality and protects their safety.

CONTINUED
Storage Practices: To establish the protocols for receiving, rotating, and
CONTINUED
storage of raw materials and managing first-in/first-out inventory of all
ingredients, packaging materials and finished products.
Set standards to which loads must arrive in order to accept the contents.
No load can be received without first inspecting the trailer, the BOL, and
RECEIVING
the contents and document the inspection on the inspection report. If
STORAGE
there are any signs of rodent or insect activity the Losurdo Foods
employee must contact the manager on duty. Once the manager inspects
RECEIVING
STORAGE
TRANSPORT
the load, he or she must report their findings to the Plant/General
TRANSPOR
T PROGRAM PROGRAM
Manager and the QA Manager. If a trailer is dirty or the products for
delivery are dirty, you must inform the manager on duty.
Temperature Sensitive Materials: If the load is temperature sensitive a
temperature must be documented on the inspection report and be less
than 41 degrees at arrival. If there are signs the trailer did not transport
the product below the maximum temperature of 45 degrees, you must
report these findings to the manager on duty. When you open the doors,
if product has visible signs of condensation, you must run a core
temperature on the must center pallet of that load. This must also be
enforced for all refrigerated liquids received at the facility.

CONTINUED
CONTINUED

Containers and Utensils: Containers (bags, cups, trays, tubs, pails, lids,
seals, and film) may only be used for their intended purpose. This is a
RECEIVING
serious violation of company GMP and Written Company Policy‟s. Do not
RECEIVING
STORAGE
use product containers for but not limited to the following: storage of
TRANSPOR
T PROGRAM STORAGE
tools, parts, chemical, drinking water, solvents, or writing instruments.
TRANSPORT
Rejection of Shipments: Losurdo foods will maintain records of all
temperature sensitive products received or rejected. These records are
PROGRAM
recorded on
“OPS.MATERIAL.HANDLING.INCOMING.INSPECTION.FORM”

CONTINUED

Allergen Control Depending on product, allergen control may be
identified as a potential hazard. It is imperative that possible allergens
ALLERGEN
and required controls specific to each manufactured product are
CONTROL
PROGRAM identified. As appropriate, requirements to ensure that products are
allergen free must be defined clearly with records maintained to
confirm compliance.

ALLERGEN
CONTROL
PROGRAM

Foreign Material Control Foreign material may be controlled by
filters, strainers, socks or sifters. Magnets are also considered a form
of foreign material control. The prerequisite program determines
placement and monitoring activities. In some operations, a unit
PHYSICAL
strategically placed in the process may be identified as a CCP.
CONTAMINATE
S
CONTROL
CONTROLLING
Whether a CCP or managed as a prerequisite, monitoring
requirements should bePHYSICAL
PROGRAM
defined and records demonstrating
compliance maintained.CONTAMINATES
PROGRAM
....A_EDAA_SQF6. SQF REQUIREMENTS FOR PRE-
REQUISITES6.9.CONTROL.OF.PHYSICAL.CONTAMINATION.PREREQUISITE.PROGRAM6.9.FOREIGN.MATERIAL.DETECTION.CAL.CHECKS(B
K).xlsx

CONTINUED

Pest Control Pest management may be included in the GMP program
or exist as a stand-alone program. This depends on how
responsibilities within the operation are assigned. If an external
supplier provides these services, ensure that requirements are clearly
PEST
MANAGEMEN communicated to the supplier and that records are maintained to
T
PROGRAM confirm not only that activities are being performed as defined, but
also that any identified pest control concerns are addressed in a
timely and effective manner.

PEST MANAGEMENT
PROGRAM

CONTINUED

Drainage and sewage systems are equipped with appropriate traps
and vents. Establishments are designed and constructed to prevent
cross-connection between the effluent of human wastes and any other
WASTE No drainage pipes pass directly over or
wastes in the establishment.
CONTROL
WASTE
CONTROL
PROGRAM PROGRAM
through production areas, unless they are controlled to prevent
contamination.
Facilities are provided for the storage of waste and inedible material
prior to their removal from the establishment. These facilities are
designed to prevent contamination.
Containers used for waste are clearly identified and are leak proof.

CONTINUED

What is Food Defense?
Food defense is not the same as Food Safety. Food defense focuses
on protecting the food supply from intentional contamination, with a
variety of chemicals, biological agents or other harmful substances by
FOOD
DEFENSE people who want to do us harm. These agents could include materials
PROGRA
M
that are not naturally-occurring or are not routinely tested for. An
attacker‟s goal might be to kill people or disrupt our economy.
Intentional acts are generally not reasonable and are hard to predict.

FOOD DEFENSE
PROGRAM

CONTINUED
CONTINUED
What is Food Defense?
Food Safety addresses the accidental contamination of food products
during processing or storage by biological, chemical or physical
hazards. The main types of food safety hazards are microbes,
chemicals and foreign objects. This unintentional contamination of
FOOD
DEFENSE
food products can be reasonably anticipated based on the type of
PROGRA processing. This principle is the foundation of the Hazard Analysis
M
Critical Control Point (HACCP) process used to ensure Food Safety
Plan and Food Quality Plans are successful but separate from Our
Food Defense Plan. ....A_EDAA_SQF6. SQF REQUIREMENTS FOR PRE-
FOOD DEFENSE
REQUISITES6.14.FOOD.DEFENSE.PLAN.PREREQUISITE.PROGRAM6.14.FOOD.DEFENSE.PLAN.VALIDATION.CHECKLI
ST.docx
PROGRAM
Also see the added articles of food related contamination paragraph 17 of “FORMING YOUR HACCP TEAM”

Training STANDARDS, SAFETY, requirementCONTINUED
is an essential HACCP & STABILITYmentioned by
the Codex Alimentarius Commission2 that is not specifically
stated as one of the seven principles. Codex
states, "Training of personnel...in HACCP principles and
applications, and increasing awareness of consumers are
essential elements for the effective implementation of
HACCP." It is imperative that associates are trained in their
TRAINING responsibilities. Qualification and competency requirements
EDUCATIONAL
PROGRAM for specific responsibilities, including those related to the
HACCP plan, must be defined with records maintained to
confirm that requirements have &
TRAINING been met. This must include
personnel on temporary assignment, individuals filling in
EDUCATION
during breaks, vacations or sick leave, even those hired
PROGRAM
through a temporary agency. Well-defined and effective
training cannot be stressed enough.

CONTINUED
Prerequisite programs can include& STABILITY chemical
STANDARDS, SAFETY, hazardous and CONTINUED
material control, sensory testing and training, control of
nonconforming product, customer complaints and internal
auditing.
Any discussion related to HACCP must emphasize management
commitment. Though management commitment is not one of
HACCP's seven principles, the Codex document
states, "Management commitment is necessary for
TRAINING
EDUCATIONAL
implementation of an effective HACCP system" and emphasizes
PROGRAM
that "the successful application of HACCP requires the full
commitment and involvement of management and the work
force." Management must convey &positive message of
TRAINING a
commitment throughEDUCATION operation in both words
all levels of the
and actions. Management should conduct formalized meetings-
PROGRAM
perhaps quarterly-to evaluate the suitability and effectiveness of
all HACCP-related activities. Any concerns or weaknesses in
these should be addressed to ensure product safety.

Personnel suffering from infectious diseases or are carriers of
any infectious disease shall not engage in product handling or
processing operation. This is covered in our GMP policy and
PERSONNEL
communicated annually at our GMP training. In
PRACTICES
addition, personnel with exposed cuts, sores or lesions shall not
be engaged in handling or processing product. Minor cuts or
PROGRAM
abrasions on exposed parts of the body shall be covered with a
PRESONNE colored band-aid.
L
PRACTICE
S
Outlined in the GMP policy is the prohibition of smoking,
PROGRAM
chewing, eating, drinking or spitting in any food processing or
food handling areas.
Clean hands are required by all of our employees. They shall be
washed by all personnel upon entering any food handling or
processing areas; after each visit to a toilet; after using a
handkerchief; after handling wash down hoses or contaminated
material; and after smoking, eating or drinking.

CONTINUED
Whenever gloves are used, personnel are required to follow
the hand washing requirements listed above.
The clothing worn by employees is maintained, stored and
PERSONNEL
PRESONNE
laundered by an outside contractor. It is to be worn so as
PRACTICES
L
PRACTICE not to present a contamination risk to product. Employees
S PROGRAM
PROGRAM
are to wear a clean set of uniforms each day. At the end of
the day, the soiled uniforms are not to be stored in their
locker, instead, they are to be placed in the used laundry
bins.

Personnel entry into processing& STABILITY
STANDARDS, SAFETY, and packaging areas is
CONTINUED
through the designated doors only. Doors throughout the
plant are on automatic closing systems and are to be kept
closed at all times. Exterior doors are kept closed and are
secured by a key fob system throughout the plant.
All personnel are required to wash their hands upon entry
into any processing or packaging area.
PERSONNE
L
Per the GMP policy, the wearing of false fingernails and
PROCESSI
NG
PRACTICES
fingernail polish is not allowed when handling food
PROGRAM
products.
Packaging material, product and ingredients are to be
PERSONNEL
stored off the floor in all areas. Wood pallets are not to be
PROCESSING
used to store material in the packaging / processing areas
PRACTICES use of plastic pallets is
for more than an 8 hour shift. The
PROGRAM
required if material is to stay in the room for an extended
period of time.

CONTINUED Waste isSTANDARDS, SAFETY, & STABILITY
collected in the labeled trash cans CONTINUED
and emptied
daily by the custodial staff. Waste at the packaging
machine machines is collected and discarded by the
operations staff throughout the day.
Evaluating products in the food handling contact zone is
not permitted. All product that is being evaluated by staff is
to be done at the designated product evaluation area. The
PERSONNE
L
PROCESSI
area is to be maintained in a sanitary manner and
NG
PRACTICES equipment used is sanitized, maintained and stored
PROGRAM
separate from processing equipment.
PERSONNEL
All wash down hoses are stored on provided hose racks
after use and not left on the floor. Nozzles are not permitted
PROCESSING
to touch the floor while in use or storage.
PRACTICES
PROGRAM

Water Quality and Water Treatment ProgramsSTABILITY
STANDARDS, SAFETY, & The internal CONTINUED for requirements
ensuring the safety of the water supply will depend on its source. An effective
UV process supported by records confirming acceptable water potability would
be necessary for well water used in production whereas a certificate of
compliance combined with periodic (i.e., quarterly, semi-annual) lab testing may
WATER QUALITY
be sufficient for city water. Keep in mind that ensuring the safety of the water
supply may also include attention to boiler additives, ice production, and other
PROGRAM
water quality/treatment activities.
WATER
Quality Control and Microbiological Testing Depending on the operation,
QUALITY
PROGRAM
various quality control/quality assurance programs (i.e., microbiological
testing, temperature monitoring, pH testing) may be included in prerequisite
programs. In most instances, these programs verify and validate the HACCP
plan. However incorporated into the plan, specific tests, frequencies and
acceptable parameters must be identified and records maintained.

All water used meets the requirements of the Pasteurized Milk Ordinance and
the federal requirements for potable water.
The water used to flush out products meets the requirement per the PMO of
pasteurized water or its equivalent. We have completed all sampling and
testing of flush points as required by the PMO and submitted results to New

CONTINUED
Preventive Maintenance Successful operations perform preventive
maintenance (PM) to ensure uninterrupted process; however, many
do this informally. A better approach is to formalize the procedures:
Identify equipment, required maintenance, frequencies, etc., then
PREMISES
document performance. Prioritize to identify critical equipment that
EQUIPMENT
MAINTENANCE must be maintained in a timely fashion, the neglect of which could
PROGRAM
jeopardize product safety, quality or overall production. A small
company may use a structured inventory system instead of a formal
PM program to ensure that there are always spare parts for the critical
equipment. The system that works best is well defined.

PREMISES &
EQUIPMENT
MAINTENANCE
PROGRAM

Calibration Any equipmentSAFETY, & STABILITY
STANDARDS, used to demonstrate compliance to a
CONTINUED

specified requirement must be calibrated. Calibration confirms the
accuracy of the equipment and should be measured against a known
standard. A master list of equipment requiring calibration,
CRITICAL
frequencies, methods, tolerances, responsibilities, etc., should be
CRITICAL
EQUIPMENT
EQUIPMENT
maintained along with the required action if an instrument tests
CALIBRATIO
NS
PROGRAM
CALIBRATIONS
outside acceptable tolerances during routine calibration. Product
tested (dating back to the last acceptable calibration check) with out-
PROGRAM
of-compliance equipment must be evaluated to ensure that it was
indeed acceptable. If calibration is an element of the HACCP plan,
prove that no food safety hazard was created. Deviations are
addressed through programs that control nonconforming product or
product recall.

This facility has a Quality Assurance Preventative Maintenance
CONTINUED
Program detailing the equipment and areas to be cleaned, along
with the frequency of cleaning. This program covers the gasket
change program, valve inspections, pump inspections, press
inspections, and many more PM programs. In addition, there is
a Master Sanitation Schedule for each room of the plant
detailing the daily cleaning of the areas and the frequency of the
cleaning. SSOP‟s are available that have been developed by our
CLEANING
SANITATIO
N
contracted cleaning company – Basic Chemical Solutions (BCS).
PROGRAM
These detail the procedures showing how to clean the
equipment including the required chemicals to be used. After
cleaning of the equipment, the &
CLEANING operator is responsible for
SANITIZING
inspecting the equipment for cleanliness. In our packaging and
processing areas, an equipment inspection is conducted prior to
PROGRAM
start up by the foreman or supervisor on duty. Spot checks are
done on the packaging equipment with an ATP swab at the end
of cleanup and spot checked prior to startup.

CONTINUED We haveSTANDARDS, SAFETY, & STABILITY CONTINUED
a detailed equipment inspection form for each of
our processing and packaging areas. As the operator
cleans an item, they document this on the form. When
complete, the on duty supervisor or leadperson do an
inspection of the equipment and sign off on the inspection
form that the work was satisfactory. If the equipment is not
CLEANING
SANITATIO
clean, it will be noted on the sheet and the equipment will
N
PROGRAM be re-cleaned until it passes inspection. In addition, a spot
check of equipment is conducted using area Swabs,
sending out to a 3rd party lab. CIP charts are reviewed and
verified each day by the quality &
CLEANING assurance department. Our
intent is to buy an SANITIZING an ATP analyzer for our
agreement for
processing facilities.PROGRAM

CONTROL MECHANISMS
Losurdo Foods, Inc. is America‟s leading Italian style cheese
manufacturing specialist. Losurdo Foods, Inc is supplying a variety of
Italian style cheeses to the food service and manufacturing industry.
Over the last fifty years Losurdo Foods, Inc. has built a reputation for
honesty, quality, and superior customer service. It is through the
determination in producing only the highest quality product that
Losurdo Foods, Inc. has become one of the premier Italian foods
COMPAN specialists of the industry.
Y
POLICIE
S
Losurdo Foods, Inc has fully committed to and execute the
principles, practices, and initiatives set forth by Global Food Safety
Initiative (GFSI), a non-for profitPOLICIES Safe Quality Foods
COMPANY organization.
Institute (SQF) has SQF 2000 System which is collaborative and
structured guidelines to Safe Quality Foods as part of the Global Safe
Food Initiative in conjunction with principles of HACCP (Hazard
Analysis Critical Control Points).

CONTINUED CONTROL MECHANISMS CONTINUED

This initiative will enhance and strengthens our current
HACCP Plan and is the foundation of the Losurdo Foods, Inc
Food Safety Program. The Code is a HACCP quality management
system that utilizes NACMCF (National Advisory Committee on
Microbiological Criteria for Foods) and CODEX HACCP
Principles and Guidelines, proven methods used by the food
industry professionals to reduce the incidence of unsafe food
COMPAN
Y reaching the marketplace.
POLICIE
S
The main objective of the company and organization is to
invest needed resources to fully and continually meet and
COMPANY POLICIES
improve the safety, quality and consistency of our product line
by the implementation of the SQF System 2000 Guidelines.
....A_EDAA_SQF-AMSTERDAM4. SQF 2000
REQUIREMENTS4.1.1.ii.1
METHODS4.1.1.1.SQF.POLICY.REQUIREMENTS.MANUAL.docx

CONTROL MECHANISMSCONTINUED
Sanitation Programs These define requirements for cleaning and sanitizing activities.
In some industries, such as juice processes, documenting these requirements in
sanitation standard operating procedures (SSOPs) is required. Obligation or not,
SANITATION
requirements for performing sanitation activities should be clearly defined in written
procedures. Training must be performed in an effective manner that ensures
STANDARD
responsible associates understand and perform all assigned tasks competently.
OPERATING
21 CFR part 178.1010. It is considered one of the prerequisite programs of HACCP.

SANITATION
PROCEDURES
For more information on the reason for SSOP history go to HACCP 1996.For
STANDARD
OPERATING regulations and inspections go to FSIS.
PROCEDUR
ES SSOP‟s are generally documented steps that must be followed to ensure adequate
cleaning of product contact and non-product surfaces. These cleaning procedures
must be detailed enough to make certain that adulteration of product will not occur.
All HACCP plans require SSOP‟s to be documented and reviewed periodically to
incorporate changes to the physical plant. This reviewing procedure can take on
many forms, from annual formal reviews to random reviews, but any review should be
done by “responsible educated management”. As these procedures can make their
way into the public record if there are serious failures, they might be looked at as
public documents because they are required by the government.

CONTINUED CONTROL MECHANISMS
SSOP‟s in conjunction with the Master Sanitation Schedule and Pre-
Operational Inspection Program, form the entire Sanitation operational
SANITATION
guidelines for food related processing and one of the primary
backbones of all food industry HACCP plans.
STANDARD
SSOP‟s can be very simple to extremely intricate depending on the
SANITATION
STANDARD
OPERATING
focus. Food industry equipment should be constructed of sanitary
OPERATING
PROCEDUR
ES
PROCEDURES
design; however some automated processing equipment by necessity
is difficult to clean. An individual SSOP should include:
•The equipment or affected area to be cleaned, identified by common
name,
•The tools necessary to prepare the equipment or area to be cleaned
•How to disassemble the area or equipment
•The method of cleaning and sanitizing

CONTROL MECHANISMS CONTINUED

2.1 Definition
An important aspect of a quality system is to work according to
unambiguous Standard Operating Procedures (SOPs). In fact the whole
process from sampling to the filing of the analytical result should be
described by a continuous series of SOPs. A SOP for a laboratory can be
defined as follows:
"A Standard Operating Procedure is a document which describes the
STANDARD regularly recurring operations relevant to the quality of the investigation.
OPERATING
PROCEDUR The purpose of a SOP is to carry out the operations correctly and always in
ES
the same manner. A SOP should be available at the place where the work is
done".
STANDARDS
A SOP is a compulsory instruction. If deviations from this instruction are
allowed, the conditions for these should be documented including who can
OPERATING
give permission for this and what exactly the complete procedure will be.
PROCEDURES
The original should rest at a secure place while working copies should be
authenticated with stamps and/or signatures of authorized persons.


Several categories and types of SOPs can be distinguished. The name "SOP"
may not always be appropriate, e.g., the description of situations or other
matters may better designated protocols, instructions or simply registration
forms. Also worksheets belonging to an analytical procedure have to be
standardized (to avoid jotting down readings and calculations on odd pieces of
paper).
A number of important SOP types are:
- Fundamental SOPs. These give instructions how to make SOPs of the other
categories.
STANDARD - Methodic SOPs. These describe a complete testing system or method of
OPERATING
PROCEDUR investigation.
ES
- SOPs for safety precautions.
STANDARDS
- Standard procedures for operating instruments, apparatus and other
equipment.
OPERATING
- SOPs for analytical methods.
PROCEDURES
- SOPs for the preparation of reagents.
- SOPs for receiving and registration of samples.
- SOPs for Quality Assurance.
- SOPs for archiving and how to deal with complaints.

CONTROL MECHANISMS CONTINUED

PURPOSE
Losurdo Foods audits processes and procedures to determine the
effectiveness of the Food Safety Program and to provide objective evidence
SELF INSPECTIONS
concerning the need for reduction, elimination and prevention of
nonconformities. SeniorREGULATORY the results of these audits to
& management reviews
ensure suitability and adequacy and to continuously improve the documented
Food Safety Program.
INSPECTIONS
SELF
INSPECTIONS
& RESPONSIBILITY
REGULATORY
INSPECTIONS Internal Audit Coordinator is responsible for creating and controlling this
procedure.
Internal auditors are responsible for planning and conducting audits and
developing records as defined in this procedure.
REQUIREMENTS
Internal audits are periodically performed to determine if the Food Safety
Program:
•Planned and scheduled by the Internal Audit Coordinator
•Audits conducted on Plant departments and their associated activities:

Scope:
Wet receiving To set up guidelines for interaction with and
reporting to different agencies and/or third party audits.
Dry receiving •NYS Ag & Markets: The General/Plant manager or the QA

Lab SELF INSPECTIONS be kept inThe records “NYSthese Markets inspections. or
Director will assist the representative/s during their visits
inspections.
will the Binder
from
Ag &
visits or inspections

Maintenance & REGULATORY These records will be kept in the main office.
•The USPH (United States Public Health) representatives
Ball production and packaging will be assisted by either the General/Plant Manager or the
INSPECTIONS QA Directormain office. the facility. USPH records will be
Loaf production and Packaging kept in the
while visiting
SELF
•USDA (United States Department of Agriculture)
INSPECTIONS
& Log Production and Packaging representatives will be assisted by either the General/Plant
REGULATORY Manager or the QA Director while visiting the facility. USDA
INSPECTIONS Marinade production and packaging records will be kept in the main office.
•FDA (Food & Drug Administration) representatives will be
Ricotta production and packaging assisted by either the General/Plant Manager or the QA
Director while visiting the facility. FDA records will be kept
Ricottone production and packaging in the main office.
•US Army representatives (Veterinary service) will be
Cheddar production and packaging assisted by either the General/Plant Manager or the QA
Director while visiting the facility. US Army records will be
Cold Storage kept in the main office.
•AIB (American Institute of Baking) third party auditor;
Shipping representatives will be assisted by either the General/Plant
Manager or the QA Director while visiting the facility. AIB
records will be kept in the main office.
•OSHA (Occupational Safety and Health Administration)
representatives will be assisted by either the General/Plant
Manager or the QA Director while visiting the facility. OSHA
records will be kept in the main office.

....A_EDAA_SQF4. SQF 2000
REQUIREMENTS4.4.4.FOOD.QUALITY.PLAN.CHECKLIST4.4.4.CQP.CHECKLIST.docx

REQUIREMENTS4.4.3.FOOD.SAFETY.PLAN4.4.3.FOOD.SAFETY.PLAN.CHECKLIST4.4.3.
FOOD.SAFETY.CHECKLIST.docm
SELF
AUDITS
& 3RD
PARTY ....A_EDAA_SQF4. SQF 2000
AUDITS
REQUIREMENTS4.5.VERIFICATION.SOP.SQF4.5.5.INTERNAL.AUDIT.GUIDE.docx

REQUIREMENTS4.5.VERIFICATION.SOP.SQF4.5.5.INTERNAL.AUDITS4.5.5.INTERNAL.A
UDIT.SCHEDULE.docx

REQUIREMENTS4.1.1.MANAGEMENT.POLICIES4.1.COMMITMENT.STATEMENT.docx

ORGANIZATIO ....A_EDAA_SQF4. SQF 2000
NAL
COMMITTMENT REQUIREMENTS4.1.1.MANAGEMENT.POLICIES4.1.COMMITMENT.STATEMENT
(SPANISH).doc

....A_EDAA_SQF9. SQF PRINCIPLES & APPLICATION OF HACCP9.HACCP.TEAM.xlsx

QUALITY IMPROVEMENT SYSTEMS
Introduction:
We can think of the „formation of the HACCP team‟ not only
from the perspective of dairy manufacturing and distribution
organization that wants to improve its HACCP program but
also from the perspective of other organizations –
governmental and non-governmental - that wish to develop
generic HACCP models or hygiene codes that are consistent
EMPLOYEE
ENVOLVMEN
T
with HACCP principles for our sub-sectors.
One of the main focuses of the global project on „Improving
TEAMS

EMPLOYEE
food safety and quality through the prevention of un-
intended results‟ has been the training of a core group of
ENVOLVMENT
staff within the organization of general principles of food
TEAMS
hygiene and in HACCP programs. This group has a two-fold
core responsibility:

CONTINUED QUALITY IMPROVEMENT SYSTEMS CONTINUED

• To design and implement further training on food hygiene
and HACCP to selected target groups;
• To participate in teams to work on the development /
refinement of HACCP models and hygiene codes for our
sub- categories of food production (this work clearly feeds
EMPLOYEE
ENVOLVMEN
T
back in to the training programs that we design and
TEAMS
implement).

....A_EDAA_SQF9. SQF PRINCIPLES & APPLICATION OF
EMPLOYEE
HACCPFORMING YOUR HACCP TEAM.docx
ENVOLVMENT
TEAMS

7
HACCP
PRINCIPLES
1.FD &
HAZARD ANALYSES
7
HACCP
PRINCIPLES
2.CRITICAL CONTROL
1.FD &
HAZARD ANALYSES
2.CRITICAL CONTROL
POINTS
POINTS
3.OPERATING LIMITS
CRITICAL LIMITS
3.OPERATING LIMITS
4.MONITORING
6.VALIDATING/VERIFING
CRITICAL LIMITS
7.RECORD KEEPING
4.MONITORING
6.VALIDATING/VERIFING
7.RECORD KEEPING

7
S Q
AFE
TY
UALI
F OODS

2 S
HACCP
PRINCIPLES
1.FD &
HAZARD ANALYSES
2.CRITICAL CONTROL
POINTS
4.MONITORING
6.VALIDATING
QUALITY
VERIFING
7.RECORD SYSTEM VERIFICATION
KEEPING
EMPLOYEE
COMMITMENT T
SANITATION TEAMS
SELF
OPERATING &
SELF
CONTROL
COMPAN
STANDARD
INSPECTIONS
OPERATING
AUDITS
& 3RD
MECHANISM
Y PROCEDUR PARTY S
POLICIE ES AUDITS
PRESONN WATER CRITICAL
S
PRACTIC PROGRA CALIBRATION
ES PERSONNE PREMISES S
M
TRAINING PROGRA L EQUIPMENT PROGRAMCLEANING
EDUCATION M PROCESSIN MAINTENAN SANITATION VALIDATION
AL G CE PROGRAM
PROGRAM
CUSTOME
PRACTICES
RECEIVING
PROGRAM
PROGRAM
R STORAGE CONTAMINAT CONTROL DS, SAFET
COMPLAIN TRANSPO ES PROGRA
TS RT CONTROL M Y, &
PROGRAMAPPROVE PROGRAM ALLERG PROGRAM PEST
TRACEABILI FOOD STABILITY

M PROGRA
M
M

Record Control HACCP's Principle Seven (see box
below) requires an "effective record keeping system
that documents the HACCP plan." Readily accessible
records must provide evidence that CCPs have been
established according to required procedures, and
prerequisite programs are maintained in an effective
manner. Without the proof (record), the activity is not
technically complete. There can be no assumptions nor
must any activity be left to interpretation. These
record-control programs should include the
identification of the records, retention
times, responsibilities, requirements for
completion, etc. These records should be completed in
permanent ink; all changes to the document must be
initialed. A strong argument can be made supporting a

Document Control An effective document control
process will include defined requirements for
preparing procedures, work instructions, forms, and
other instructional documents. It should also define
requirements for revising and distributing documents.
A master list of all documents that includes the current
revision status of each document and its distribution
must be maintained. This ensures all obsolete
documents are retrieved and replaced with current
versions. Distribution may include hard-copy versions
(maintained in binders or posted in high-traffic areas)
or accessibility through computer terminals. Having
current requirements accessible where needed will
prevent needless problems.

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