Important aspects to be kept in mind while preparing Food Safety &
Quality Manual:
Policy: Organizations policies to be framed
Organizations overall and departmental Quality Objectives in measurable terms to be
framed
Identifying the positions and competencies (education ,relevant experience) needed
for performing the work to be documented
Recruiting the personnel meeting the requirements as documented above
Organization chart and roles & responsibilities to be documented
Total layout of the plant in building to be kept including men and material movement
Identifying each machine in plant and preparing inputs to the machine and output
from the machine to be documented
Process flow chart for manufacturing process from raw material inputs to the finished
products and its storage and dispatch to be documented
Training programs needed to the personnel as per manufacturing processes and
processing of training as per these documented requirements to be ensured
Handling of customer complaints on the products and its mechanism to be
documented
Ensure that all the requirements of the respective standard is addressed in the
manual. To ensure this it is better to prepare a matrix indicating the requirements on
the one side and compliance documents in the manual can be given
Normally the following procedures will be documented irrespective of the standard
being implemented.
•
Control of records
•
Recruitment of personnel
•
Training of personnel
•
Management review meeting
•
Internal audits
•
Handling customer complaints
•
Corrective action
•
Preventive action
•
Handling of potentially unsafe product / non conforming product
•
Verification & validation
Raw material and finished product specifications has to framed
Procedure for supplier evaluation
eFresh Portal made an effort to prepare a Food Safety Manual Structure based
on HACCP guidelines, which is generic and the same can be considered as a first
step towards preparation of the Food Safety Manual and incorporating the
requirements as applicable in individual case.
SAMPLE
-FOOD SAFETY
MANAGEMENT SYSTEM MANUAL
ISO 22000:2005
Prepared by: Approved by:
Effective from:
TABLE OF CONTENTS
S. No Documents Document No Clause No. Pages
1 Contents FSMS – C - 2 Abbreviations FSMS-A - 3 Company Profile FSMS –C P - 4 Declaration FSMS – D - 5 Distribution List FSMS – DL - 6 Amendment List FSMS – AL -
8 Scope of the FSMS FSMS – S 01
9 References FSMS – R 02
10 Terms and Definitions FSMS – TD 03
11 Documentation Requirement FSMS – DR 4.2
12 Control of Documents FSMS – CD 4.2.2
13 Control of Records FSMS – CR 4.2.3
14 Management Responsibility FSMS – MR 5.0
15 Food Safety Policy FSMS – FSP 5.2
16 FSMS Planning FSMS – FSMSP 5.3
17 Responsibility & Authority FSMS – RA 5.4
18 Food Safety Team Leader FSMS – FSTL 5.5
19 Communication FSMS – C 5.6
20 Emergency Preparedness & Response FSMS – EPR 5.7
21 Management Review FSMS – MR 5.8
22 Resource Management FSMS – RM 6.0
23 Competence Awareness & Training FSMS – CAT 6.2.2 24 Training & Training Plan FSMS – T&TP 6.2.2.3 25 Infrastructure & Work Environment FSMS – IWE 6.3-6.4 26 Planning & Realization of Safe Product FSMS – PRSF 7.0
27 Pre- Requisite Programs FSMS – PRP 7.2
28 Pre. Steps to Enable Hazard Analysis FSMS – PSEHA 7.3
29 Product Characteristics FSMS – PC 7.3.3
30 Intended Use FSMS – IU 7.3.4
31 Flow Diagram FSMS – FD 7.3.5
32 Hazard Analysis FSMS –HA 7.4
33 Hazard Assessment FSMS –HA 7.4.3
34 Control Measures FSMS –CM 7.4.4
35 Operational PRPs FSMS –OPRP 7.5
36 HACCP Plan FSMS –HP 7.6
37 Updating-Verification- Traceability FSMS –UVT 7.7-7.8-7.9 38 Control of Non-Conforming Product FSMS –CNCP 7.10 39 Validation, Verification & Imprv. of FSMS FSMS –VVIF 8.1-8.2 40 Control of Monitoring and Measurement FSMS-CMM 8.3
41 FSMS verification FSMS-FSMSV 8.4
ABBREVIATIONS ABBREVIATION EXPANSION ACCT ACCOUNT ADMN ADMINISTERATION AMDT AMMENDMENT AMT AMOUNT ANNX ANNEXURE APPX APPENDIX ATT ATTACHMENT BAL BALANCE B/F BROUGHT FORWARD
BIO BIOLOGICAL
C CONSEQUENCES
CP CONTROL POINT
CCP CRITICAL CONTROL POINT
CHEM CHEMICAL
CONTD CONTINUED
DT DATE/ DATED
EFF EFFECTIVE
ENCL ENCLOSURE/ ENCLOSED
FSM FOOD SAFETY MANUAL
FSMS FOOD SAFETY MANAGEMENT SYSTEM
FSSP FOOD SAFETY STANDARD PROCEDURES
FSTL FOOD SAFETY TEAM LEADER
GMP GOOD MANUFACTURING PRACTICES
I/C INCHARGE
HACCP HAZARD ANALYSIS AND CRITICAL CONTROL POINT
HR HUMAN RESOURCE
IDEN IDENTIFICATION
INFRA INFRASTUCTURE
ISO INTERNATIONAL ORGANIZATION FOR STANDARDIZATION
L LIKELIHOOD
MAINT MAINTENANCE
MAX MAXIMUM
MIN MINIMUM
PHY PHYSICAL
PRP PRE-REQUISITE PROGRAMS
PREP PREPERATION
P & S PROCUREMENT & SUPPLIES
PROD PRODUCTION
QC QUALITY CONTROL
QMS QUALITY MANAGEMENT SYSTEMS
QTY QUANTITY
R RISK
SOP STANDARD OPERATING PROCEDURES
SSOP STANDARD SAFETY OPERATING PROCEDURES
STD STANDARD SUPVSR SUPERVISOR TPT TRANSPORT VR VOUCHER WE WORK ENVIRONMENT WT WEIGHT YR YEAR
AMENDMENT LIST Sl. No Document Name Document Number Date of Amendment
COMPANY PROFILE
• About Company: Should cover Geographical details
• Number of branches if any
• About production facility
• At this hotel, all three meals are served – Breakfast, Lunch and Dinner. Variety of cuisines - South Indian, North Indian and International with both Vegetarian and Non-Vegetarian options are prepared at the Kitchen and served in the Cafe. The Kitchen also has a live counter where Pizzas and Pastas are made to order with options. The Menus are displayed in the restaurant so that guests get to know the options available for the day.
• At this hotel, we are committed to making constant improvements to the quality and hygiene standards of the food served to our guests.
DECLARATION
XYZ Hotels brings out this Food Safety Management System Manual as part of the food safety system under the authority of the Manager. This Manual is the original and authenticated one and the activities detailed in this Manual are true and correct. This FSMS Manual is in compliance with the international standard, ISO 22000:2005 which it is based on. The criteria outlined in this Manual are mandatory and shall be complied with by all the facility staff of this hotel.
Any changes or modifications to be incorporated in this manual shall be made only upon authorization by the MR and the details of the modifications by the food safety team leader will be indicated in the record of Amendments.
Date:
Signed by: MR
DISTRIBUTION LIST
The Controlled copies of the FSMS Manual are distributed to the following holders:
Controlled copy no. Authorized Holders 01 Executive Chef 02 Manager QC 03 Manager (F & B)
The MR holds the “Master Copy” of the FSMS Manual.
AMENDMENT LIST Sl. No Document Name Document Number Date of Amendment Clause No. Reason for Change Authorization 1 2
a. Form of License No. (PFA)
SCOPE OF THE FSMS
The FSMS system in xyz is applicable to the activities undertaken in the food service establishment at……, Hyderabad. The scope is as follows:
“Food Production and service”
• ISO 22000:2005 SYSTEM
We have developed an ISO 22000 based Food Safety Management System which assures the safety of meals prepared at xyz premises .Process control plans developed and operated for all aspects that are applicable to the safety of foodstuffs are described/ referenced in the appropriate ISO 22000 Food Safety System documentation.
The Scope of the ISO 22000 System at xyz has been defined as per the position within the food chain, as per process location and line, and per product and includes all classes of hazards viz. Physical, Chemical & Biological.
REFERENCES
• Food Safety Management Systems – Requirements for organizations through out the food chain. – ISO 22000 : 2005
− General Principles of Food Hygiene, CAC/RCP 1-1969, Rev. 4 (2003), amended 2003.
− Hazard Analysis and Critical Control Point (HACCP) System and Guidelines for its Application, Annex to CAC/RCP 1-1969, Rev. 4 (2003).
• The Prevention of Food Adulteration [PFA 1954 Act]
TERMS AND DEFINITIONS
• Action-limit value - A value for the product or process parameter under consideration, deduced
from the critical limit value, which indicates that an intervention in the process is required.
• Aspect- An element of the food business operation (products, processes, PRP, services) that can
interact with the food safety.
• Contaminant - Any biological or chemical agent, foreign matter, or other substances not
intentionally added to food which may compromise food safety or suitability
• Contamination - Introduction or occurrence of a contaminant in food or food environment.
• Control (verb) - To take all necessary actions to ensure and maintain in compliance with criteria
established in the Food Safety Plan.
• Control (noun)- The state wherein correct procedures are being followed and criteria are being
met.
• Control measure- Any action and activity that can be used to prevent or eliminate a food safety
hazard or reduce it to an acceptable level.
• Control measure, general- A measure to control a specific part of the PRP.
• Control measure, specific- A measure to control a CCP.
• Corrective Action - Any action to be taken when the result of monitoring at the CCP indicate a loss
of control.
• Critical Control Point (CCP) - A step at which it is essential that a specific control measure is
applied to prevent or eliminate a Food Safety Hazard or reduce the risk to an acceptable level.
• Critical Limit - A criterion, which separates acceptability from unacceptability.
• Note- This criterion defines the limiting values for the product or process parameters under
consideration for monitoring (see action- limit vales and target value).
• Disinfection - The reduction, by means of chemical agents and/or physical methods, of the number
of micro-organisms in the environment, to a level that does not compromise food safety or suitability
• Establishment - Any building or area in which food is handled and the surroundings, under the
control of the same management.
• Flow Diagram - A systematic representation of the sequence of steps or operations used in the
preparation, processing, manufacturing, packaging, storage, transportation, distribution, handling or offering for sale of a particular food item.
• Food business operator- The person or persons responsible for ensuring that the requirements of
the food legislation are met within the food business under his/ their control.
• Food handler - Any person who directly handles packaged or unpackaged food, food equipment
and utensils, or food contact surfaces and is therefore expected to comply with food hygiene requirements
• Food Hygiene – All conditions and measures necessary to ensure the safety and suitability of food
at all stages of the food chain.
• Food safety - Assurance that food will not cause harm to the consumer when it is prepared and/or
eaten according to its intended use.
• Food suitability - Assurance that food is acceptable for human consumption according to its
intended use.
• HACCP- A system, which identifies, evaluates and controls hazards which are significant for food
safety.
• HACCP audit- A systematic and independent examination to determine whether the HACCP system,
including the HACCP plan and related results, comply with planned arrangements, are implemented effectively and are suitable for the achievement of its objectives.
Note- Examination of the Hazard Analysis is an essential element of the HACCP audit.
• Food safety Plan- A document prepared in accordance with the principles of HACCP to ensure
control of hazards, which are significant for food safety in the segment of the food chain under consideration.
• HACCP based food safety system (a HACCP system) - The organizational structure, procedures,
processes and resources needed to execute the HACCP plan and meet its objectives.
• Food Safety Team- Group of individuals (multi- disciplinary) who develop, implement and
maintain a Food Safety Management system.
• Hazard - A biological, chemical or physical agent in or condition of, food with the potential to cause
an adverse health effect.
• Hazard Analysis - The process of collecting and evaluating information on hazards and conditions
leading to their presence to decide which are significant for food safety and therefore is addressed in the Food safety plan.
• Monitoring - The act of conducting a planned sequence of observations or measurements of control
parameters to assess whether a CCP is under control.
• Pre-Requisite Program (PRP)- Any specified and documented activity or facility implemented in
accordance with the Codex General Principle of food hygiene, good manufacturing practices and appropriate food legislation, in order to establish basic conditions that are suitable for the production and handling of safe food at all stages of the food chain.
• Preventive action- Any measure or activity that will be used to prevent, to eliminate or to reduce
the recurrence of causes for existing deviations, defects or any other undesired situation with respect to food safety.
• Primary production - those steps in the food chain up to and including, for example, harvesting, • Products, unprocessed- Foodstuffs which have not undergone a treatment, including products
which have been, for example, divided, parted, severed, boned, minced, skinned, ground, cut, cleaned, trimmed, husked or milled, chilled, frozen or deep frozen.
• Product, processed- Foodstuffs resulting from the application to unprocessed products of a
treatment such as heating, smoking, curing, maturing, pickling, drying, marinating, extraction, extrusion, etc or combination of these processes and or products; substances necessary for their manufacture or for giving specific characteristics to the products may be added.
• Risk- The probability of causing an adverse health effect caused by the occurrence and the severity
of a particular hazard in food when prepared and consumed according to its intended use.
• Target value- The value of the product or process parameter(s) to be monitored, targeted within
action- limit values (the range of acceptable variations) and certainly within critical limit values, thus securing a safe product.
• Step - A point, procedure, operation or stage in the food chain including raw materials, from
primary production to final consumption.
• Validation - Obtaining evidence (in advance) that the specific and general control measures of the
Food Safety plan are effective.
• Verification - The application of methods, procedures, tests and other evaluation, in addition to
monitoring to determine compliance with the specification laid down in the HACCP Plan and the effectiveness of the HACCP – based food safety system.
Food Safety Management System Documentation Structure
: The documentation structure consists of different hierarchical levels as follows:• Food Safety Policy Manual
• Standard Operating Procedures
• Work Instructions / operating Rules
• HACCP Principles related documents
• Miscellaneous documents
• Formats and Records
4.0FOOD SAFETY MANAGEMENT SYSTEM 4.1General requirements:
4.1.1 The Food Safety Management System (FSMS) documented by XYZ in this Food Safety
when required and also its effectiveness is continually improved in accordance with the requirements of ISO 22000:2005.
4.1.2 XYZ has defined the scope of the FSMS as in FSMS Manual – Clause1.0 and has identified the product categories, processes and production sites where this FSMS is implemented.
4.1.3 As part of the FSMS, XYZ has
• Ensured that all food safety hazards expected to occur in the products or processes within the scope of activities of the system are adequately identified, evaluated and controlled based on the HACCP system developed so that the products produced are safe and do not harm the consumer.
• Proper communication (external) throughout the food chain within its scope of activities and purview with respect to the food safety issues of the products it produces.
• Proper communication (internal) throughout the organization regarding the FSMS development, implementation and updating as required by the standard – ISO 22000:2005.
• In place FSMS review meetings (once a year) to evaluate and update it on a regular basis and/or whenever required to incorporate the latest information on the hazards associated with its products and processes which need to be controlled.
4.1.4 XYZ has outsourced some of the processes like external lab services, pest control, water and other materials and calibration of testing and monitoring devices for machine testing of food that are identified and are under the control of XYZ.
4.2 DOCUMENTATION REQUIREMENTS
4.2.1 General
The Food Safety Management System documentation consists of
• Documented statements of Food Safety Policy and Food Safety Objectives in this FSMS Manual.
• Food Safety Management System Manual
• Documented Food Safety Management System Procedures/Food Safety Manual as required by ISO 22000:2005 and other procedures needed to ensure effective planning, operation and control of the processes by the organization are included in this FSMS Manual or referenced here as to where such procedures are documented. Forms and Formatted registers needed to generate records are
indicated. List of records maintained meeting the requirements of ISO 22000:2005 are also part of the XYZ documentation requirements.
• The FSMS Manual is prepared covering
- Scope of FSMS, covering the exclusions, if any, with justification.
Reference to Food Safety Management System Procedures and Food Safety Manual.
4.2.2 Control of documents
• Procedure for Document control is established for effective control of documents defining the following controls
- To approve the documents for adequacy prior to the use.
- To review and update as necessary and re approve documents
- To ensure that changes and the current revision status of documents are identified.
- To ensure that relevant versions of applicable documents are available at points of use.
- To ensure that documents remain legible and readily identifiable.
- To ensure that documents of external origin are identified and their distribution controlled and
− To prevent the unintended use of obsolete documents, and to apply suitable identification to them if they are retained for any purpose.
• The documents are updated with PRPs and HACCP plan
• Records are considered to be a special type of document, which provide objective evidence to
fulfillment of requirements of the Food Safety Management Systems. Effort would be to maintain the records in the electronic media
• Records are established and maintained to provide evidence of conformity to requirements and of the effective operation of the Food Safety Management System. The records are maintained in such a way that they are legible, readily identifiable and retrievable.
• At XYZ, the Procedure for Control of records has been established with regard to :
- identification - storage - protection - retrieval - retention time - disposition 5.0MANAGEMENT RESPONSIBILITY 5.1Management commitment
The Management of XYZ demonstrates good commitment to the FSMS development and implementation and continually improve its effectiveness
• By communicating the importance of meeting the customer requirements as well as statutory and regulatory requirements through meetings.
• By ensuring establishment of Food Safety Policy
• By ensuring that Food Safety/Quality Objectives are established
• By conducting Management Review Meetings.
• By ensuring that all necessary resources are available to carry out the operations.
• XYZ has defined and documented its policy with regard to food safety, thereby demonstrating the
organization’s commitment to safe food. It is focused on the safety of foodstuffs, and responds to the expectations and needs of its consumers.
• XYZ ensures that the policy & objectives are understood, implemented and maintained at all levels of the organization. This is done through suitable means like displaying on boards and conducting meetings, via departmental heads, etc. Employees are advised of the policy & objectives on joining the company and/or during trainings. Food Safety Policy forms the basis for formulation of Food Safety/Quality Objectives.
• Food Safety Policy and Food Safety/Quality Objectives are reviewed in Management Review Meetings once in 6 monthsto ensure their continuing suitability.
FOOD SAFETY POLICY
Policy statement:
The Food Safety Team in M/S.XYS Company is committed to serving food to its guests prepared under hygienic and safe conditions.
Our Food Safety Practices shall:
• Ensure that only Trained and Skilled staff are inducted into the kitchen
• Reflect Food Safety Standards in relation to safety practices, premises and equipment standards
• Reinforce consistent food safety practices in the service
• Aim at providing Safe and Hygienic food
• Reduce the risk of potential food-borne illnesses
• Comply with legislative requirements while maintaining a flexible approach to meet the best practices
• Reflects continual improvement in the Food Safety Standards.
This commitment to Food Safety Policy will be demonstrated by the management conforming to Food Safety Management System based on ISO 22000:2005 requirements and the following objectives as mentioned in the table on the next page.
Organization Chart
Highlighted is the HACCP team
Managing
Director
Production
Manager
Manager QA
Manager
Procurement
Plant
Operators
Microbiologist
Stores in
charge
Supervisor
Hygiene Supervisor
Electrician
Maintenance
in charge
Ripening shed in chargeHR
Manager
Competency of each position in the organization can be documented in the below
format. Any of the employees working in the organization is not complying with the
requirements set by the organization as per the standard if any, and the
organization’s operational requirements, then the position is not confirming to the
requirement.
Therefore it is very important that the organization first determines the competency
requirement of the personnel, as per the operational requirement and then recruit
the people complying with this requirement.
Format for COMPETENCY MATRIX
Sl.
No.
Name of
Employee
Function
/
Designati
on
REQUIRED
ACTUAL
Academic
Qualification
Total
Experien
ce
Skill
set
Academi
c
Qualifica
tion
Total
Experien
ce
Skill
set
FOOD SAFETY AND QUALITY OBJECTIVES AT FUNCTIONAL LEVELS FOR THE PERIOD OF 2011-2012 S S..NNOO FUFUNNCCTTIIOONN OBOBJJEECCTTIIVVEE RERESSPPOONNSSIIBBIILLIITTYY LLEEVVEELL ( (FFuunnccttiioonnaall HHeeaaddss)) 1
1 HRHR To give employees, a minimum of one training program in a month in handling, processing, and serving of the safe food.
M
Maannaaggeerr QQCC
2
2 PPuurrcchhaassee // SSttoorreess Nonconforming input materials
not more than 5% per supplier of the total consignment per month
M
Maannaaggeerr SSttoorreess
3
3 PrProodduuccttiioonn // MMananuuffaaccttuurriinngg To bring down the wastage of the food to 5 % of the total production.
E
Exxeeccuuttiivvee CChheeff
4
4 PrProodduuccttiioonn // MMananuuffaaccttuurriinngg To monitor and maintain safe temperatures (>63°C) while hot holding of food. E Exxeeccuuttiivvee CChheeff 6 6 QuQuaalliittyy AAssssuurraanncce e CuCussttoommeerr ccoommppllaaiinnttss:: NNoott mmoorree t thhaann 55%% ppeerr mmoonntthh M Mananaaggeerr FF && BB
5.3 Food Safety Management System Planning
The Top Management of XYZ ensures that
• The Planning of the Food Safety Management System is carried out in order to meet the requirements of ISO 22000 standard and Food Safety/Quality Objectives.
• The FSMS Planning of XYZ ensures that the requirements (inputs) are clearly documented to ultimately meet the acceptance criteria (output).
• The FSMS Planning includes or refers to the Flowchart, Worksheets, Quality Control Plans, Food Product Specifications/Recipes and Hazard Identification.
• The integrity of the Food Safety Management System is maintained when changes to the Food Safety Management System are planned and implemented.
• On conducting a hazard analysis and Determination of the Critical Control Points (i.e., meeting the first two HACCP principles), the HACCP Plan becomes the input for planning activities with focus on what areas need control and to what level.
• The requirements of the product are analyzed and defined with regard to :
- Documentation: Flowchart, Worksheets, Quality Control Plans, Food Product Specifications/Recipes and Hazard Identification with Critical Control Points
- Equipment: includes the manufacturing / food production equipment
- Human resources: All staff has the appropriate skills for the jobs / tasks
- Purchased materials: Availability of the raw materials, ingredients to the specified requirements and manufacturing aids
5.4Responsibility and Authority
• The Organization Chart included in this manual shows the relationships between the respective functions.
All staff and managers are responsible for the quality of their own work and for advising
their respective workers of their work responsibilities, when satisfactory operation of the FSMS is adversely affected. Staff and managers are responsible and have the authority within their defined areas of control for:
- The quality of work carried out
- Initiating action to prevent the occurrence of product non-conformance
- Identifying and recording quality problems
- Initiating, recommending and providing solutions to quality problems
- Verifying that solutions are effective
- Controlling further processing until all conditions are satisfactory
• Further details of responsibilities and authorities for personnel who manage and perform the work can be found in the relevant job descriptions or related documents.
• In the event of absence, responsibility and authority passes to the next higher level of management, for subsequent delegation, as appropriate.
Food Safety Team Responsibilities
• Making of the flow charts, their hazard analysis and determination of CCP, conduction of HACCP Verification and Validation.
• Ensuring that the HACCP system is operating and maintained in XYZ as per the ISO 22000:2005 standards.
• Providing adequate guidance and training to all for carrying out their duties in the raw material reception, pre-preparation areas, processing areas, raw material stores and all other sections as per XYZ approved HACCP Plans, procedures, and operating methods.
• Effective implementation and monitoring of cleaning schedule and strict personnel hygiene measures in the XYZ
Validation Team Responsibilities
• Ensuring the adequacy, completeness, and (scientific) basis of the potential hazards identified and analysed.
• Ensuring that the aspects considered while determining the significance of hazards are evaluated using sound scientific and technical knowledge
• Ensuring that the control measures (general or specific) are appropriate and adequate to control the hazards
• Ensuring that the fluctuations of the control parameters (equivalent to process criteria) within the defined critical limits will not affect the safety of the product
• Ensuring the appropriateness of the control measures’ monitoring system
• Ensuring the appropriateness of the corrective action systems defined, w.r.t. preventing the release of unsafe products, and that they provide evidence that the situation can be corrected immediately.
• Ensuring that the Food Safety System is validated first and every time prior to issue.
• Ensuring that all the validated activities are carried out in time and records of the same are maintained.
• This is in addition to their existing responsibilities.
5.5 FOOD SAFETY TEAM LEADER
Executive Chef of M/s.XYZ Company is the nominated FS Team Leader having responsibility and
• Ensure that processes needed for the Food Safety Management System are established, implemented, maintained and updated.
• Report to the top management on the performance of the Food Safety Management System and any need for improvement
• Ensure the promotion of awareness of customer requirements throughout the organization.
• Liaison with external agencies on matters relating to the Food Safety Management System
• First ensure relevant training and education to FST members
• To organize internal food safety audits for FSMS and review corrective action if required, through follow up audits.
5.6. COMMUNICATION 5.6.1 External Communication
• XYZ has ensured that appropriate communication processes are established with the customer, Legal Authorities and External Certifying Agencies.
• XYZ communicates with the customers in relation to:
- Product information.
- Customer complaints and feedback are documented and Corrective and Preventive Actions are taken accordingly.
• All the data required for Legal authorities and External certifying agencies is recorded and maintained separately.
5.6.2 Internal Communication
• XYZ ensures that appropriate communication processes are established within the organization and that communication takes place regarding the effectiveness of the FSMS through:
- Management Review Meetings, minimum once in six months
- Notices/Mail.
- Circulars
• The preventive actions identified under hazard analysis and the food product deviations with the related dispositions are made known by communicating at the appropriate levels and functions.
• At XYZ communication takes place with regard to the following to promote effective operation of the FSMS:
- recipe improvisations / new recipes
- changes in raw materials, ingredients
- changes in food production, manufacturing systems, equipment and surrounding environment
- changes in the requirements (customer, statutory / regulatory)
- changes in personnel qualification level and responsibilities
- New food safety hazards with the new ways of handling and controlling measures.
- Changes in cleaning and sanitation programmes, storage and distribution systems
- Complaints indicating food safety hazards associated with the products.
• The food safety team ensures that this information is included in the updating of the FSMS.
• Top management shall ensure that relevant information is included as input to the management review
• The minutes of the Management Review Meetings are maintained by the MR. (Refer Minutes of Management Review meetings)
• The minutes of meetings are communicated to the participants of the meeting for taking effective actions and demonstrating continual improvement
5.7. EMERGENCY PREPAREDNESS AND RESPONSE
• Objectives of the Plan
To identify the possible hazard/ risk this can lead to environmental emergency, property damage and injury to human beings
- To prevent, identified potential environmental, food safety related emergency scenarios
- To minimize /mitigate consequences wherever possible.
- To provide relief to injured persons.
- To control the emergency as early as possible.
• Potential Emergency Situations.
Location Factors leading to emergency
Hazard Preventive measures
Raw/packing Material storage Electrical Fire Bidi/Cigarette Fire Injury to human Beings Air pollution Land Pollution Proper connections
‘NO SMOKING’ sign is displayed. Fire extinguishers & pipelines are provided
Electrical Control Panel Area
Flash due to short Circuiting
Overloading and water Spillage Fire Injury to human beings Air Pollution Proper connections Proper load distribution Area to be kept dry
‘NO SMOKING’ sign is displayed. Production
Area
Fire
Manual handling of chemicals
Accidental spray of hot CIP Solutions Steam burns Water Pollution Air pollution Injury to human beings
Proper maintenance of pipe Fittings
Kitchen area Fire
Leakage of LPG Electrical sparks
Fittings & electrical short Circuit
Lighted cigarette, match Sticks.
Fire & explosion Air pollution Property damage Injury to human Beings.
Regular maintenance of gas Pipe fittings.
‘NO SMOKING’ sign is Displayed.
Fire extinguishers& Pipelines are provided.
Monitoring of LPG
Admn.block. Sites of high rise Building
Painting/ Construction / Civil work
Slip or fall may lead to an accident
Injury to human beings
Safety belt, proper ladder, Proper scaffolding
Cleaning of glasses
Slip or fall may lead to an Accident
breakage of glass
Injury to human beings
Safety belt, proper ladder
• Potential Food Safety Emergency
Location Factors leading to emergency
Hazard Preventive measures
Production/ Kitchen Area
Bio-terrorism, sabotage, Bird flu
Injury to Human Beings
Entry restricted to Production / kitchen area Security Arrangements in the premises round the clock.
Raw materials/commodities are accepted only after proper checking.
Finished Product is released only after proper checking.
Microbiology lab is in the premises; however routine bacteriological used media / culture are disposed off only after auto-claving.
Service center Premises
Energy Failure Accidents Product Loss & Timely
Delivery effects
Emergency Lights provided at the potential areas. Standby Generator/Transformer.
Service center Premises Flooding Unhygienic Conditions and hindrances to production.
Proper Maintenance of drainage system & periodically cleaning.
Additional pumps provided around the premises to throughout storm water / additional water outside the premises.
All the premises is covered with solid brick walls and entry gates are raised, then the road level to stop entry of water from outside.
• Emergency Preparedness:
- To deal with fire, the whole premises are equipped with fire extinguisher pipelines and fittings etc... Which are installed at various locations as per the law.
- Majority of the persons in the service centre trained in fire fighting and first aid is displayed prominently in every department.
- All security guards are trained in fire fighting.
- Adequate number of first aid boxes are installed and maintained in the service centre.
- All inflammable materials are stored in isolated place and labeled accordingly.
- ‘NO SMOKING’ signs are displayed at all important locations
- Intercom facilities are available all over the building for communication with security department.
- Personal protective are kept near potential area by the concerned Section In charge such as hand gloves, masks etc.
- List of emergency telephone numbers is available in each department.
• All types of wastages like raw material, packaging material etc is taken by an external agency for disposal of the same.
• Other waste like cooked leftover food items are taken by an external agency for disposal and records are maintained.
• For Product recall from customer please refer clause 7.10.3 (handling of potentially unsafe products)of this manual
5.8 MANAGEMENT REVIEW 5.8.1 General
Top management reviews the organization’s Food Safety Management System at least once in every six months to ensure its continuing suitability, adequacy and effectiveness. The review includes assessing opportunities for improvement and the need for changes to the Food Safety Management System, including the Food Safety Policy and Food Safety Objectives. Records of management review are maintained.
• The members of the Management review committee include: Manager QC
Manager Purchase & stores Manager Production
5.8.2 Review input
The input to the Management review meeting includes the following information.
• Follow-up actions from previous management reviews
• Analysis of results of verification activities
• Changing circumstances that can affect food safety
• Results of review and system updating activities
• Communication activities including customer feedback and is reviewed monthly.
• External audits or inspections
5.8.3 Review output
Output of the management review contains the decisions and actions related to
• Assurance of food safety
• Improvement of the effectiveness of the Food Safety Management System
• Resource needs
• Revision of organization’s food safety policy and objectives
Management Representative
• The Management Representative, ensures the following: As per standard
- To establish, implement and maintain the FSMS as per ISO22000: 2005 Standards.
- To ensure that processes needed for the FSMS are established, implemented and maintained understanding the current and future needs of the customers / clients
- To report to the top management on the continuing suitability and effectiveness of the FSMS and the scope for improvement
- To promote awareness of customer requirements throughout the organization
- To plan, schedule and conduct Internal Audits for FSMS
- To select qualified Internal Auditors
- To review the Audit Report and follow-up Corrective Action / Preventive Action Reports
- To initiate modifications of documents based on Corrective action / Preventive Action and to control all the documents related to the FSMS
- To schedule management review meetings at the defined intervals and record minutes of management review meetings for subsequent reporting on the performance / improvements of the FSMS
- To liaison with the external agencies related to the FSMS Implementation and Certification
• The Management Representative convenes the management review meetings after preparation of the agenda and maintains the minutes of the meeting.
6.0 RESOURCE MANAGEMENT
6.1 Provision of Resources :
• Resources (Human resources, Equipment resources and Work environment needs) required for implementation & maintaining of Food Safety Management System are identified, and determined by MR for carrying out various activities as per budgeted plan.
• Resources are provided to implement and maintain the Food Safety Management System and continually improve its effectiveness and enhance customer satisfaction by meeting customer requirements. Resource requirements are reviewed in Management Review meetings.
• The resources include :
- Adequate trained personnel for management, performance and verification activities.
- input materials of the requisite quality
- Suitable process equipment, process control equipment and other infrastructure to meet the requirements for the quality of the product.
- Work environment (physical and human) suitable for operation / processes to meet up Quantified Quality Objectives.
6.2 HUMAN RESOURCES
6.2.1 General
• XYZ provides competent personnel for performing work affecting product quality. Competency of the personnel is based on appropriate education, training, skills and experience and is established in line with the Food Safety and Quality Policy and Plans. All staff working in food areas is adequately trained in hygiene procedures.
6.2.2 Competence, Awareness and Training
a. Competence of personnel for performing the activities having Quality, Safety and Environment impacts has been established on the basis of appropriate education, training and or experience. b. Enhancement of competence is done through training, education and learning involving technical
knowledge and skills, management skills and tools, social skills, knowledge of markets and customer needs and expectations, relevant statuary and regulatory requirements, internal and appropriate external standards, and documentation for performing the work as appropriate.
Efforts are made to increase the awareness and involvement of personnel through programs which covers:
- the vision for the future of the organization,
- the Organization’s policies and objectives,
- organizational change and development,
- The initiation and implementation of improvement activities,
- introductory programs for new personnel, and
- Periodic refresher programs for personnel already working with the organization.
c. Identification of training needs
- The Organization analyses the development needs of all its personnel and design training plan for them. This is to provide personnel with knowledge which, together with skills and experience, leads to competence.
Preparation of training plan
For identified training, training plans are prepared. The training plan covers:
-food safety training,
-personnel hygiene,
-hygiene and sanitation,
-pest control,
-Operation of equipment
(Refer: Training Plan Tables in this Manual)
d.Imparting training and keeping records
- In coordination with concerned function training is imparted either by deputing persons to identified institutions outside or by organizing in house training by engaging trainers from outside agencies or from within the organization.
- The technical personnel have been trained on principles of ISO: 22000-2005 and are also on the use of documentation related to the Organization's FSMS.
- Competence and training records of personnel are maintained on prescribed formats. Effectiveness of the training is assessed and records are maintained.
e. It is the responsibility of the Department Heads to identify the training needs of their personnel on the basis of work performance, introduction of new process and technology and recommend them for training such as external training, seminars, workshops etc. The workers have also been trained on basic quality concepts, food hygiene and good manufacturing practices and food safety.
f. The food handlers have the necessary knowledge of food handling and preservation principles and practices to be able to judge potential risks and take the necessary actions by effective communications to remedy deficiencies.
g. Training Plan for Professional Skills for the Year 2011
Topics to be covered Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
GMPs – facility issues, food flow, people flow, waste flow, building and structural issues, segregation, cross contamination due to
facility issues
SSOPs – cleaning of all areas/equipments/utensils etc, personal hygiene, cross contamination, pest
control, water safety, health issues etc
CCP related –
identification, critical limits, monitoring, corrective action, record keeping, verification and validation
Process related – Non-conformity, corrective actions, internal audits, unsafe product handling, control of documents and records, traceability, product recall and emergency situations.
Production related – receiving, issuing, storage, cooking, steaming, baking, frying, dispatch, hot/cold holding, etc
Basic food hygiene – basic principles of handling food
Personal hygiene – Hand wash procedures, Uniform, personal grooming, proper use of accessories,
reporting illness and medical health
HACCP – as per Codex
ISO 22000:2005 - Awareness Training
ISO 22000:2005 – Internal Auditor’s training
Basic Fire Safety Training
Basic First Aid Training
6.3 Infrastructure :
• XYZ determines, provides and maintains the infrastructure needed to achieve conformity to product requirements.
• Infrastructure at XYZ includes :
- Building, workspaces and associated utilities like UPS, generators, air–conditioners, air-compressors, etc.
- Calibrated process equipment.
- Supporting services like telephones, fax m/c, computers, etc.
- Appropriate design and maintenance of the work area, which has a major effect on food safety. The maintenance of the equipment complies with the Good Manufacturing Practice (GMP) and Good Laboratory Practice (GLP)
• Infrastructure is maintained to ensure their suitability. Equipment maintenance is carried out as per schedule established.
• Work environment needed to achieve conformity to product requirements is provided at all working places in the organization.
• To ensure safety of personnel, activities related to safety is carried out like periodic medical checkup and safety awareness trainings, hygiene training programmes etc.
PLANNING AND REALIZATION OF SAFE PRODUCT 7.1 General
• XYZ Plans and develops the processes needed for Product Realization. Planning of Product Realization is consistent with the requirements of the other processes of the FSMS. The processes are clearly defined with the measurement criteria and the interfacing with the other processes.
• The results of HACCP study is taken as input to Process Planning / Food Safety Planning, with the critical areas and shows the correct directions. The results from Food Safety Planning give an indication of the typical controls needed within a process. Food Safety Planning is linked to the HACCP Plan in which the CCP’s were identified.
• To ensure Product Realization, consideration is given to associated support functions as well as desired outputs, materials, methods, equipment, control measures, information, training needs and other resources. Support functions include :
- Training of people
- Availability of infrastructure
- Application of Industrial safety / Protective Equipment
• XYZ determines the following while planning for product realization:
- Food Safety & Quality Objectives and requirements for the product.
- The need to establish processes and documents and provide the resources specific to the manufacturing of the food product.
- The required verification, validation, monitoring, inspection and test activities of the food product and the criteria for the product acceptance.
• Records needed to provide evidence that the realization processes and the resulting product meet requirements.
• In planning, the following problems / risks are considered which can occur during processing :
- Risk of contamination – for raw materials, additives. Work-in-progress, final products and packaging materials
.
7.2 PRE-REQUISITE PROGRAMS
7.2.1 XYZ has made available a complete and actual description of the pre-requisite program (PRP) of
the organization. The PRPs establish
- The likelihood of introducing food safety hazards to the product through the work environment.
- All classes of hazards (biological, physical and chemical) of the product/process, including cross contamination between the products.
- The level of food safety hazards in the product and product processing environment.
7.2.2 XYZ has identified the PRP’s as per the organizational needs, appropriate to the type of operational
and product manufacture along the production system. And PRP’s are approved by Food Safety Team in compliance with PFA too.
7.2.3 XYZ has made available
• The procedures belonging to the PRP are well established (specified and documented), fully operational and integrated with the ISO 22000:2005 system, and verified. Their verification is addressed as a part of the Internal Audits and Verification activities.
• XYZ has decided which food hygiene principles, good manufacturing practices and food legislation are to be included into its PRP.
7.3 PRELIMINARY STEPS TO ENABLE HAZARD ANALYSIS 7.3.1 General
• The products and the processes, (the procedures belonging to) and the PRP are subjected to hazard analysis in order to identify potential hazards and to decide which way the hazards (risk) need to be controlled. This is demonstrated in the Hazard Identification and Risk Analysis of related products/processes, in the related HACCP/Food Safety Plans, as applicable. All the relavant information is collected, maintained, updated and documented. Records are available for the same.
7.3.2 Food safety team
• XYZ has assembled a Food Safety Team in order to develop, implement and maintain the ISO 22000 System. The team definition is available in the Food Safety Team document maintained with the FSTL. The team members have the knowledge, expertise and cover different disciplines available which are required to develop, implement and maintain a Food Safety Management System covering the entire scope of their operation. The competency of Food Safety Team Members is available and maintained with the FSTL, and is reviewed & updated periodically.
• The assignment (including tasks, responsibilities and authorities) are documented for the team members of the Food Safety Team as a part of the Responsibility and Authority document maintained with the FSTL.
7.3.3. PRODUCT CHARACTERISTICS
7.3.3.1& 7.3.3.2 Raw materials, ingredients and product contact materials & characteristics of end products
• The quality specifications are defined for raw materials and ingredients. The product description for various food groups is specified and documented. The description of the safety of the product group encompasses the food chain, ranging from raw materials used to the distribution of the finished products. This is further documented through the Flow Diagrams and Hazard Analysis Work Sheets for the product group respectively
• An extensive specification of the end products ensures a comprehensive assessment of the food safety procedures. This specification clearly defines the following product characteristics:
− Product identification and general product description.
− Raw materials used and composition.
− General product specifications as per recipe.
− Specific requirements such as appropriate legislation.
− General control of (chemical, microbiological and physical) for food safety.
− Packaging, storage conditions, labeling.
7.3.4. INTENDED USE
• The intended use of the product is identified and documented for the product groups. Since this has a direct influence on the required product characteristics.
• The intended use of the product is continually reviewed.
7.3.5. FLOW DIAGRAMS, PROCESS STEPS AND CONTROL MEASURES
7.3.5.1 Flow diagrams
• XYZ has made available a complete and actual description of the operation in the form of flow diagrams (process steps), which are included in Food Safety Manual for the Flow Diagram, and layouts (production facilities), which are available with the FST Leader. When applying ISO 22000 to a given operation, consideration is given to steps preceding and following the specified operation, which is evidenced in the flow diagrams and Hazard Identification & Risk Analysis worksheet. These descriptions are drawn up and verified by the Food Safety and Validation Teams.
• The Flow Diagrams provide a schematic overview of the operation, and describe all the steps in sufficient detail to provide the Food Safety Team with adequate information for the ISO 22000. They take into account all relevant process steps, such as the manufacturing of the product, including critical points like:
− Disinfection of vegetables before use
− Pre-preparation
− Cooking
− Serving
• All facilities which are part of the infrastructure of XYZ, such as the production lines, storage areas and personnel facilities are depicted in layout plans. In the layout plans, the following items have been indicated:
− The routing of material, personnel. This is shown in the PLANT Layout.
− The areas and facilities for personnel use. This is shown in the PLANT Layout.
• Prior to the execution of changes in the production process and layout that could adversely affect food safety, these changes are reported to the Food Safety Team in order to evaluate potential hazards to food safety, and take preventive actions accordingly. Prospective changes are reported to Food Safety Team as per the Documentation Control Procedure and its supporting documents.
• The accuracy and actuality of flow diagrams and layouts are verified by the Food Safety Team for compliance with the documented situation on a periodic basis (at least annually), in order to identify and document modifications to the process installation and layout. Verified flow diagrams and layouts, with changes marked on them if applicable, are maintained with the FSTL. These periodic verifications are a part of the Internal Audit cum Verification.
7.4 HAZARD ANALYSIS 7.4.1 General
• XYZ has identified, analysed and evaluated all potential (biological, chemical and physical) hazards that can have an adverse effect on the safety of the products. Wherever XYZ’s operations change in a manner that could adversely affect food safety, all relevant steps of the Hazard Identification and Risk Analysis are updated (as necessary).
7.4.2 Hazard Identification & Determination of Acceptable Level 7.4.2.1
• XYZ Food Safety Team has identified and registered all potential (biological, chemical and physical) hazards that can have an adverse effect on the safety of the products. The identification includes all aspects of the operation within the scope of the ISO 22000 system. Potential hazards have been documented in the Hazard Analysis Worksheet.
• The operations evaluated include all products, all processes and the pre-requisite program of the legal owner of the products
7.4.2.2
• FS Team Members shall identify and record all the potential hazards during food
preparation, processing and delivering (biological, chemical and physical) that may have an adverse effect on the safety and hygiene of the food product.
• The hazard identification includes aspects like:
- Raw materials and ingredients: specifications, vendor approval, etc;
- Characteristics of end products: product specifications, etc;
- The Pre Requisite Program, including OPRP’s
- Facilities Layout, Production Lines, Installations and Equipment
- Production processes, like: purchasing, cleaning and disinfection, packaging, maintenance, pest control, waste management, etc.
- Personnel (including arrangements for visitors and external service providers, e.g.: mechanics): hygiene, knowledge with regard to food hygiene and food safety, requirement to notify diseases and infections, etc.
- Process Parameters
• The identification of hazard with details of type, source, and process step and whether it is biological, chemical or physical hazard are defined in hazard analysis worksheet. The source of hazards (i.e, the root cause) at each processing step is subsequently taken up for analysis for elimination of the same.
7.4.2.3 Hazard Analysis (Risk)
• FS Team Members shall identify, analyze and evaluate all potential hazards
(biological/microbiological, chemical/ physical) that can have adverse effect on the safety of the food product.
- The likely occurrence of hazards and severity of their adverse health effects
- The qualitative and/or quantitative evaluation of the presence of hazards,
- Survival or multiplication of microorganisms of concern,
- Production or persistence in foods of toxins, chemicals or physical agents, and
- Conditions leading to the above.
• The hazard analysis process is for identifying hazards, determining the risks and control/ reduction of the risk is the risk management.
RISK MANAGEMENT PROCESS Hazard Identification
Resp: FS Team Members
- shall list all hazards and define its characteristics (Refer Hazard Analysis worksheets)
Hazard Analysis (Risk Assessment) Resp: FS Team Members
• Hazard analysis serves to identify the potential sources and specific points of contaminants by analysis of each step in the food manufacturing process. Hazard analysis shall be applied at all points from incoming material inspection to consumer.
• Hazard Analysis has been conducted by the Food Safety Team based on the Flow Diagrams. Methodology followed for arriving a hazard is as follows:
- Number all steps in the flow Diagrams
- Verify each step of flow Diagrams for possible physical/chemical and Biological/Microbiological hazards
- Assess the likelihood of the hazard
- Asses the consequence / severity of the incident.
- Based on the above, level or risks have been evaluated. All the risks are included with the help of group discussions by Food Safety Team and other associates from relevant areas.
- The likely occurrence of the identified hazard, evaluated quantitatively, in terms of Very High, High, Medium or Low and likelihood of occurrence, as follows:
LIKELIHOOD/ PROBABILITY CONSEQUENCES/ SEVERITY RISK / LEVEL
Improbable (eg. 5- 10 years)
1 Rarely
1-4/very Low
Unlikely (eg. yearly)
2
Minor (eg. Light injuries etc.)
1
5-6/Low
Occational (eg. Monthly/4-6 Monthly)
3
Medium (eg. Injuries, stomach pain, uneasiness )
2
7-9/ Medium
Likely (eg. Weekly/Monthly)
4
Major(eg. Illness, Hospitalization)
3
10-12/ High Risk Control / Reduction
Resp: FS Team Members
- programme
Frequently (eg. Daily/ Weekly)
5
Critical (eg. Death, Permanent disability)
4
15-20/Very High
(Refer Hazard Analysis Worksheet Annexure-7.4 of this manual on following pages)
DETERMINATION OF RISK AND SEVERITY OF HAZARDS
1. Probability of occurrence
Very High > automatically happen High > Likely to happen Medium > could happen
Low > Not likely to happen 2. Severity of each hazard
Critical > Will frequently result in unsafe product Major > Will likely result in unsafe product Medium > May result in unsafe product Minor > Will not result in unsafe product
Determination of significance
SEVERITY
PROBABIL ITY
MINOR MEDIUM MAJOR CRITICAL
LOW XXXXX XXXXX ////////////////////// /////// ////////////////////// /////// MEDIUM XXXXX XXXXX ////////////////////// /////// ////////////////////// /////// HIGH XXXXX ////////////////////// /////// ////////////////////// /////// ////////////////////// ///////
VERY HIGH ///////// //// ////////////////////// /////// ////////////////////// /////// ////////////////////// /////// 7.4.3 Hazard Assessment
• The severity of the hazard’s adverse health effects, evaluated quantitatively, in terms of critical, major or minor impact severity, as follows:
• The risk rating, in quantitative terms (arrived at by multiplying the probability of occurrence with the severity of impact), and the classification of the identified hazard into significant or non-significant category based on the risk-rating factor. A risk rating of 10 or above indicates that the control measure is required to control the identified hazard.
SEVERITY PROBABILITY MINOR 1 MEDIUM 2 MAJOR 3 CRITICAL 4 LOW (unlikely) 2 5 9 10 12 MEDIUM (occasionally) 3 7 10 12 15 HIGH (Likely) 4 9 12 15 17 VERY HIGH (Frequently) 5 12 15 17 20
• An explanation / justification for the risk rating arrived at, together with the general control measures in place for that risk.
• A risk level of below 10 is generally considered as permissible and the routine OPRP’s and PRP’s are sufficient to control the hazard.
7.4.4. Selection and assessment of control measures
• XYZ food safety team has identified and documented the control measures that are to be applied or implemented when the hazard identification and risk analysis exercise concludes that the risk of an identified hazard is significant and needs to be prevented, eliminated or reduced to an acceptable level.
• For each step, including all products, all processes and all parts of the PRP, the assessed aspects have been identified in the Hazard Analysis Worksheet and HACCP Plan. The reasons for deciding whether or not the assessed aspect is a CCP or an Operational PRP, or a PRP have been documented, as answers to the control measure assessment matrix.
• In XYZ’s Food Safety System, more than one control measure may be required to control a hazard, and more than one hazard may be controlled by a control measure.
• The food safety team has conducted an assessment of every step of the process, and has identified the significant hazards through the use of control measure assessment matrix. The assessment is based on, amongst other things, the varied expertise within the team, and has utilized external and internal information (as needed).
CONTROL MEASURE ASSESSMENT MATRIX
Probability of Failure of Control Measure
Very High Frequently- Daily or weekly High Likely – Weekly or Monthly
Medium Occasionally – Monthly or 4-6 Monthly Low Unlikely – Yearly
Consequence in case of failure of Control Measure
Very High Definitely affects the end product High affects end product
Medium May affect end product
Low Marginal impact on end product not affecting the food safety
Feasibility / Frequency of Monitoring
High Continuous
Medium At defined Frequency Low Once during the process
Is Control measure specifically designed
Yes More than 10
No Less than 10
• If the rating of the control measure assessment exceeds 10 the process step is considered as a CCP. If the rating falls between 7– 10 it is considered as an Operational PRP. And the rating below 7 is considered as PRP.
• On completion of the hazard analysis, the hazards associated with each step of the food production shall be listed along with any measures to control the hazards. More than one control measure, if required to control a hazard, shall be identified and documented and more than hazard may be controlled by a specific control measure.
• The control measures shall be identified through the requisite Program/Operational Pre-requisite Programs. Any additional measures shall be identified during the HACCP implementation to ensure that the required control is achieved to eliminate or reduce the identified hazard / risk. The reason for deciding a CCP shall be documented.
• The level of risk shall guide the Food Safety team in identifying the level of control.
Risk Level Level of Control
15-20 Very High Avoidance/ Special Process
10-12 High Physical control / Monitoring
7-9 Medium Formal Control
5-6 Low Informal Control
1-4 Very Low Training
TRAINING: Training and teaching of the staff responsible for the process about what is to be done in order to prevent the hazard.
