Successful HACCP Plan (C Kingsbury) 3 Apr 2002.pdf

Developing & Implementing a
Successful HACCP System
By Clive Kingsbury
QA Manager, Schneider Foods
3 April 2002
Clive Kingsbury Schneider Foods 1

HACCP Recognition
lSchneider Foods in Surrey HACCP
Recognized on March 18th 1999.
lOur Distribution Centre in Coquitlam was
HACCP Recognized on August 12th 1999.
Clive Kingsbury Schneider Foods 2

Agenda
lWhat is HACCP
lRoad to HACCP Recognition
lThe Benefits of HACCP
lSome pointers on what it takes to be
successful in HACCP
lWhy HACCP?
Clive Kingsbury Schneider Foods 3

What does HACCP Stand for:
lH azard
lA nalysis
lC ritical
lC ontrol
lP oints
Clive Kingsbury Schneider Foods 4

What is HACCP
HACCP is a program which provides food
processors with a systematic approach to
identify and monitor possible sources of
microbial, chemical and physical
contaminants
Clive Kingsbury Schneider Foods 5

HACCP:
lInitially developed by Philsbury in the
1960’s for the aerospace industry
lCodex and in Canada FSEP have tailored
HACCP for the food industry
lFocused on preventing hazards from
contaminating food
lBased on sound science and has become the
standard for food safety in North America
Clive Kingsbury Schneider Foods 6

HACCP:
lThe best known food safety program around
lPermits more efficient and effective
government and customer inspections of
your record keeping
lAssists companies to compete more
effectively in a world market
lMost effective method of maximizing
product safety
Clive Kingsbury Schneider Foods 7

HACCP:
l365 Day a year program
lCost effective
lTargets resources to critical areas of
processing
lParticipation of all employees in a company
thereby creating a team atmosphere
Clive Kingsbury Schneider Foods 8

What is a CCP
A CCP is defined as any point or procedure in
a specific food system where loss of control
may result in an unacceptable risk.
Clive Kingsbury Schneider Foods 9

Biological Hazards
lPathogenic Bacteria
lViruses
lParasites
Clive Kingsbury Schneider Foods 10

Chemical Hazards
lAdded Chemicals
lFood Chemicals
lNon Food Chemicals
Clive Kingsbury Schneider Foods 11

Physical Hazards
lHair
lWood
lGlass
lMetal
lPlastic
Examples Are:
Clive Kingsbury Schneider Foods 12

Allergens
l Peanuts and Tree Nuts
l Sesame Seeds
l Dairy Products
l Wheat
l Fish & Shell Fish
l Eggs
l Soy Products
l Sulphites
Clive Kingsbury Schneider Foods 13

Hind site 20/20 vision
lHACCP is a food safety program.
lUnwavered senior management
commitment
lHACCP takes years to implement correctly.
lStrategically plan for HACCP
lPrepare the company and all employees for
progress
Clive Kingsbury Schneider Foods 14

The Road to HACCP
lBe Proactive
Recognition
lBegin with the End in Mind
lPut First Things First
lCreate a Win/Win situation
lFirst Understand, then be Understood
lSynergize
lSharpen the Saw
Clive Kingsbury Schneider Foods 15

The Road to HACCP
Recognition Contd.
lStart off Broad
lFine tune later
lGet everyone involved and committed
lPrepare the company for change
lAllow everyone to grieve the loss of how
you use to do things
lManage the transition
lEmbrace the new way of producing food
Clive Kingsbury Schneider Foods 16

The HACCP Team
lCertified HACCP co-ordinator
lMulti-disciplined
lMulti-leveled
lSub-teams
lThe Whole Plant MUST be involved in the
HACCP Development
Clive Kingsbury Schneider Foods 17

HACCP Software
lWe use HACCP Software but it is not
imperative
lWord, Excel and other software is just as
effective
lA data base will be really helpful when you
make changes and updates to SOP’s and
formula
Clive Kingsbury Schneider Foods 18

Documentation
lAll activities must be documented in the
form of Standard Operating Procedures
(SOP’s)
lThis Will Help Standardize Your Product
for Consistency and Quality
Clive Kingsbury Schneider Foods 19

3 Key Programs
lNotice of Change (NOC) Program
lNon Compliance Program
lLabel Approvals
Clive Kingsbury Schneider Foods 20

HACCP Foundation
Pre-requisite Programs
lPremises
lTransportation & Storage
lEquipment
lPersonnel
lSanitation
lPest Control
lRecall
Clive Kingsbury Schneider Foods 21

HACCP Foundation
lTake care of as many Hazards as you can in
your prerequisite programs so as to:
– Reduce the number of CCP’s required in your
HACCP Programs
lAvoid repetition in your different HACCP
Programs. We have a receiving and a
blending program which support and feed
our other HACCP Programs
Clive Kingsbury Schneider Foods 22

4 HACCP Programs
lReceiving
lBlending
lCooked Meats
lFresh/Frozen
Clive Kingsbury Schneider Foods 23

HACCP Benefits
HACCP:
lAllows a company to take control of their
process
lAllows you to identify hazards and hence
control them
Clive Kingsbury Schneider Foods 24

HACCP Benefits Contd.
HACCP:
lEnables you to know what to do when
things go wrong
lReduces wasted costs due to a decrease in
rework, tankage, seconds, etc.
Clive Kingsbury Schneider Foods 25

HACCP Benefits Contd.
HACCP:
lImproves product shelf life
lDecreases end product testing
lReduces the amount of shortages
lReduces the chance of product recalls
Clive Kingsbury Schneider Foods 26

HACCP Benefits Contd.
HACCP:
lAllows you to meet and exceed government
standards
lIS OUR OBLIGATION TO OUR
CUSTOMERS
Clive Kingsbury Schneider Foods 27

HACCP Benefits Contd.
HACCP:
lIt is your companies job security insurance
plan. You take charge of your companies
destiny
lProduct quality/ consistency improves
because of the implementation and or
enhancing of SOP’s
lReduce risks from suppliers
Clive Kingsbury Schneider Foods 28

HACCP Benefits Contd.
HACCP:
lImproved customer confidence in your
product. Consumers are becoming more and
more aware and conscious of food safety
and HACCP
Clive Kingsbury Schneider Foods 29

HACCP Cons
lIt has a high front end load cost
lYou can loose some flexibility BUT gain
more control
lIt can create initial “Change Stress”
lOngoing Costs
Clive Kingsbury Schneider Foods 30

Verification
lIs critical to ensure that your program is
running the way it was intended to
lOpportunity to identify weaknesses in your
program or were more personnel training is
required
Clive Kingsbury Schneider Foods 31

Scientific Validation
lTo ensure that you are accomplishing your
goal of pathogen elimination particularly in
Ready to Eat Areas
lStatistical Process Control (SPC)
Clive Kingsbury Schneider Foods 32

Summary
lHACCP is the best known food safety
program around
lHACCP is based on sound Science
lWhat you put into your HACCP Program is
what you will get out of it in the end
lIt is OUR obligation to OUR customers
Clive Kingsbury Schneider Foods 33

CONCLUSION
HACCP IS AN
INVESTMENT IN
YOUR COMPANIES
FUTURE
Clive Kingsbury Schneider Foods 34

Where to get more information
lBCIT training sessions
lCFIA FSEP Generic Models
lConsulting services
lGuelph University
lOther
Clive Kingsbury Schneider Foods 35