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Food Safety Programs
What is a Food Safety Plan
• A , food safety plan is concerned with proper food handling systems,
which include cleaning and sanitation as an integral part of the
system.
• It is a system based on the Hazard Analysis Critical Control Points,
HACCP. (Pronounced hassup) It is a 'paddock to plate' approach
designed to identify and control food safety hazards in advance.
• The Pillsbury Company developed the HACCP system for the US
space program in the 1960’s and proved to be so successful, food
manufacturing adopted the principles and now most production
plants around the world follow these principles today.
• It is, in principle, Quality management in food production and
processing.
• Every step of the process is broken down into a "product flow" that is
then used to identify the hazards and preventative measures at each
of the steps.
Food Safety Program
• A Food Safety Program is a written plan, which shows
how food safety and hygiene is managed in the food
production plant. There is no one Food Safety Program
that suits one plant.
• Simply put, a Food Safety Plan is designed so that all
staff in a production plant not only Know what they are
doing but also can Show to council and auditors what
they are doing — "KNOW and SHOW"
• Food Safety is EVERYBODY’S responsibility, but before
you do anything, always check with your Supervisor or
Manager. If you are in doubt of what to do, isolate the
product (put it aside) and get your supervisor/ manager.
Hazards and how they can be
controlled
• A hazard is anything that may be in the product (that’s not supposed
to be) that can cause harm to the consumer either through injury or
illness. Hazards may be biological, chemical or physical and are the
basis of every Food Safety System.
• When looking at hazards, look at each step and ask yourself, what
can go wrong here? Look at all products and steps in the processRaw material, packaging, water, etc. Process - Equipment used,
Premises - Building, environment, People - Operators, Procedures
— Methods. When you look at a FSP, you will find that the steps
have been broken down into a Process Flow Chart.
• The process flow chart identifies each step in the process and the
hazards that are associated with each step and what needs to be
done to control them.
Types of Hazards
Biological
• Most quality food processing operations will be exposed to one or
more biological hazard! These come either from the raw materials or
during the process.
• Biological hazards, such as the presence of flies or insects, while
unpleasant if found, rarely pose a risk themselves to product safety
in its true sense. There are a few exceptions to this, such as
poisonous insects, but on the whole the appearance of biological
hazards such as a fly, simply causes revulsion, many times this type
of hazard is linked to Physical Hazards.
• Pathogenic Microorganisms make people sick when they eat them.
These organisms are usually spread through poor practices, dirty
equipment, sick handlers and the presence of insects and vermin.
These types of organisms are invisible to the eye and the food still
looks good and smells good and even tastes good, but it isn’t.
Some microbes in food:
Micro-Biological Hazard
Source/ found
Possible Preventative measures
Staphylococcus aureus
Hands/ wounds
Hand washing, cover wounds, gloves
L. monocytogenes
Green leafy Vegetables
Wash in clean sanitised area
Rinse with chlorinated water
Bacillus cereus
Starch (Rice/ Pasta)
Proper cleaning and sanitation
Cool product quickly
Salmonella
Protein (Poultry/ meat)
Evidence of control during supplier process.
Clostridium. Perfringens
Wet product (sauce/ stocks)
Control of time that ingredients, Freezing (—18ºC),
heating (>76ºC)
Clostridium Botulinum
Canned products
Lethal heat treatment during process
Giardia intestinalis
Water
Appropriate water supply, testing, Water filtration
E Coli
Meat
Raw meats held at 5° C, good personal hygiene
Hepatitis
Water
Appropriate water supply, testing, Water filtration
Things that help microbiological growth;
Moisture (water): Bacteria don’t grow where it is dry.
pH: If the product is kept in a strong acid such as vinegar, bacteria don’t grow.
Temperature: If the temperature is too cold (less than 5° C) or too hot (above 60° C)
bacteria won’t grow.
Oxygen: Most bacteria need air to survive, but some bacteria can live happily in a nonoxygen environment, like Clostridium Botulinum can grow in an unopened can.
Time: When bacteria are in their preferred temperatures (above 5° C and below 60° C)
they will DOUBLE in number every 20 minutes or so.
Chemical Hazards
• These are often looked on as the most important
by the consumer but in they often pose a lower
health risk. Proper cleaning and maintenance,
together with proper training in the use of
chemicals and food additives should ensure
minimal risk to end products. However, you must
be careful of things such as allergens, (nuts,
MSG) that may cause people to have an allergic
reaction. Some chemicals that can affect
products includes:
Chemical Hazards
• Food additives: Such as preservatives, MSG etc
• Pesticides: Used in baiting pests in the plant
• Detergents: Used to clean equipment and not
washed off correctly
• Plastic Wrap: Used to package product and has
been contaminated by pests
• Agricultural Sprays: Used in farm production of
raw products
Physical Hazards
• Physical hazards may not make the
consumer sick, however it may cause
injury to the mouth, intestines or just make
the customer ‘feel ill’ if , for example, they
found a hair in the product. The main
source of complaints from customers and
end users, about physical food
contamination, include.
Hair, Glass, Metal, Stone, Wood, Plastic,
Insects, Sabotage and Personal effects.
Physical Hazards
Hazard
Possible Preventative measure
Chemical spills
Separate storage area for chemicals
Contaminated Equipment
Proper cleaning and maintenance
Stones, stalks, pips, nutshells,
In/ end process Inspection
Pins, staples, hair clips, Metal shards
In/ end process Inspection/ Metal detection/
Jewellery/ personnel policy
Pests
Pests pellets, Pest control program
Allergens
Eliminate/ Clearly list on product specs
Chemical additives
Maximum legal usage levels
Glass
Elimination of all glass except Glass
lighting, which must be covered
Preventative measures
• As part of a quality approach, once hazards have been
identified, they can then be eliminated or controlled to
ensure that the product is safe for the customer to
consume.
• Preventative measures are things that we can do to stop
or minimise the hazard from occurring. These are all
usually in the Food Safety Plan and can be found in
there as Standard Operating Procedures, (SOP), Good
Manufacturing Procedures (GMP) or perhaps Work
Procedures. These procedures usually cover areas such
as Storage, Housekeeping, Waste Control, Pest Control,
Cleaning and Sanitising and Personal Hygiene.
Preventative measures
• The preventative measures rely on the fact that work
practices are followed and monitored. The food safety
plan offers little protection to the end product if staff are
lax in their work practices or do not properly clean and
sanitise equipment and surfaces, don’t report problems
to their supervisors or check the process steps as they
are required to do.
• In most plants, team meetings and reviews are held
regularly (once a week/ fortnight) to ensure that any new
problems or issues or any others that have arisen
previously are reviewed and preventative measures put
into place to stop the problems or hazards happening
again.
Team meetings
• In most plants, team
meetings and reviews are
held regularly (once a
week/ fortnight) to ensure
that any new problems or
issues or any others that
have arisen previously
are reviewed and
preventative measures
put into place to stop the
problems or hazards
happening again.
Housekeeping
• Good storage, housekeeping and pest control
procedures ensures that hazards are stopped before
they occur.
• By following all procedures such as checking machinery
at regular intervals for proper operation helps to
minimise physical hazards such as metal shavings or
lubricating grease entering the product.
• Making sure all areas of the production area are kept
clean and tidy and free from hazards such as
unnecessary product, or personal belongings, or
cleaning equipment etc.
• Finally by ensuring that all storage areas are well kept,
product is protected, covered and cleaned, the risk of
pests is greatly minimised. Finally don’t forget, if you see
any signs of pest activity, report it to your supervisor.
Cleaning and sanitising
• Cleaning and sanitising also play an important
role in preventing hazards in the processing and
food production area.
• If all areas of the plant are not properly cleaned
and sanitised, then there will be a greatly
increased chance of contaminating product,
leading to food recalls and even the chance of
food poisoning and the very big risk of very bad
publicity that could ruin a business.
• Always make sure that you follow your
companies cleaning and sanitising procedures
and complete the schedule or cleaning roster
when you are finished.
Other factors that can be
addressed in the Food Safety Plan
• - pH and acidity ; The more acid, the less risk of bacterial
growth
• - water (water activity/ moisture) - salt, sugar, drying;
• - The less moisture a product has the less risk of
bacterial growth
• - Chemical preservatives: Food industry approved and
used to extend product life
• - Storage conditions: Stored products are at risk, such
as, if a product that is made to be kept at 4° C is kept at
10° C, then the product will be at risk
• Packaging: Packaging can contaminate products if they
are contaminated by pests or the fact that recycled paper
is not to be used to wrap food as it contains many metals
absorbed when it is being pulped. So the right and clean
packaging must be used
Critical Control Points (CCPs)
• A critical control point (Food Safety Point) is a
step, process or procedure at which control can
be applied to prevent or eliminate a food safety
hazard, or reduce it to an acceptable level.
• For example: Some food operations such as in
the dairy industry thermally process food to 74°
C. This is identified as a critical control point
because if not done correctly, pathogens may
grow.
CCPs
• Other businesses may regard storage of food in covered
containers as a critical control point. If product is not
covered it may become contaminated with foreign
objects, or cross contaminate with microorganisms by
poor handling or using dirty equipment. Cross
Contamination is the commonly used term for the way in
which harmful bacteria or other hazards are passed onto
food that is ready for consumption, or clean preparation
equipment or surfaces.
• Contamination can occur by poor storage, handling,
cleaning, storing raw and prepared ingredients together,
and not cleaning preparation areas, sneezing on
product/ surfaces, using dirty utensils. Each business will
identify different critical control points, dependant upon
their production process or product range.
Monitoring CCP’s
• CCPs are an essential part of a quality production system for end
product safety. A CCP must be followed to prevent/reduce/eliminate
hazards. They must be adhered to for consumer safety. If the step is
not a CCP, it will be a Control Point, (CP).
• A CP ensures that control is maintained, for example, cleaning may
not be a CCP but it definitely is a CP, if control is not maintained
then the product may be compromised.
• The simplest way to determine if the step is a CCP, you must ask, If
control measure is not applied, is it highly likely that a health risk
will occur?
• - Yes = CCP - No = CP
• In your workplace your CCP’s will be identified and they will vary,
however, it’s usually easy to identify what CCP’s apply. These areas
are usually checked and monitored by someone, things like the Cool
room temperatures, Pasteurization temps, Delivery temps etc, they
are easily measurable.
• If something goes wrong at any of these steps, the products will be
checked, product moved or used quickly or in the worst case,
disposal of the product in question, by the right person
Monitoring CCP’s
• CCP’s can be monitored in a number of ways. It will depend on the
process and products that you produce, however, a CCP can be
checked by:
• using a temperature probe to check a cool room or process line,
using a clean and sanitised probe, as described by the procedures
in your plant.
• swabbing benches/ lines to check if they are cleaned and sanitised.
The swabbing is usually done at the end/ start of the production
process and helps to ensure that all surfaces in the plant not only
look clean and sanitised, but also are!
• Or by visually checking the equipment and the gauges to ensure
that they are meeting the required temperatures. This usually is
done during the production process and ensures that all product
coming through / out of the equipment is meeting minimum
temperature requirements
Critical Limits:
• These are the points that must be met for every
preventative measure that is linked with a
Critical Control Point. A Critical Limit is the
minimum standard / temperature/ limit that you
will need to meet and then record this as part of
your system.
• These limits are usually given to you in the form
of monitoring temperatures or cleaning and
sanitising procedures. These limits are usually
developed by government bodies such as
ANZFA, published scientific research or state
and federal hygiene standards. Its part of your
job to ensure that hazards are kept to an
acceptable level.
The example below refers to
cooking a seafood patty;
Process Step
CCP
Critical Limit
Cook
Yes
Patty Thickness 1.5 cm
Patty Composition: 80%
seafood mix, 20% Food
Grade Binder
Cooking Temp: Internal 75° C
Cooking Time: 25 mins @
Critical limits
• The critical limits described above have been
checked so that the product meets all the above
points. Make sure that you don’t accidentally
cross contaminate the product when you monitor
or check it as this defeats the purpose of the
food safety plan.
• Always use a clean and sanitised temperature
probe and ensure that all other monitoring,
cleaning and sampling equipment is always
cleaned and sanitised after each use and before
the next check.
Corrective Action
• As part of a Quality management system, corrective
actions are used to tell us what needs to be done if
something goes wrong, remember always ask your
supervisor, however, they usually cover;
• A corrective action is important as it is important to stop
a problem BEFORE the product reaches the customer. It
is better to find the product and dispose of a small
quantity (always check with your supervisor!)
• As we know, Food Safety is EVERYBODY’S
responsibility, but before you do anything, always check
with your Supervisor or Manager. If you are in doubt of
what to do, isolate the product (put it aside) and mark it
and get your supervisor/ manager.
Corrective actions
• Corrective actions must be documented (written down)
as to what was done when the problem was found and
how the problem was stopped in that instance and what
actions were put into place to stop the problem reoccurring in the future. Reporting and following up
corrective actions is an important part of any quality
management system so as to be able to follow up all
incidents. If things are not reported and recorded, then
how can you check?
• Most Corrective Actions are written onto an "Incident
Report Form" or a "Corrective Action report form". To
ensure that the problem has been stopped, supervisors
and managers must always follow up the Corrective
Actions.
Recording and Reporting
• As part of a quality management approach, a Food Safety Plan is
designed to give us a system to be able to check that things are
being done. Recording and reporting are an important parts of the
process.
• There are two basic types of monitoring procedure:
• 1. On-line systems, where CCPs are checked during the process.
• These may be continuous systems where critical dates are
continuously recorded or where observations are made at specified
time intervals during the process.
• 2. Off-line systems, where samples are taken for measurement of
the critical factors elsewhere. Off-line monitoring has the
disadvantage that the sample taken may not be fully representative
of the whole batch.
Remember, you can use a variety of tools to monitor and check, this
would include temperature probes, data loggers, cleaning and
sanitising schedule, swabbing (testing the surfaces for the amount of
bacteria, if any, is present and at what levels), sample testing, pest
control schedules, wastage forms etc.
record keeping vary examples
include the following
• Temperature monitoring
• Monitoring and recording temperature
of goods being received
• Production schedule is being
maintained/ met
• Swabs of the environment are being
completed
• Corrective actions taken and the follow
up actions for the corrective actions
• Cleaning, sanitising and maintenance
schedules
• Training records
• Staff illness monitoring
• Taking and freezing samples of the
product. These are just a few
examples.