Developing a Food safety Plan

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Developing a Food safety Plan
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What do you do with FSP
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14 steps and 7 HACCP principles

• These are
• Write a Food safety policy
• Provide information about the Firm
• Responsibility chart
• 1. Assemble the HACCP Team
• 2. Describe the product
• 3. Identify the intended use
• 4. Construct a flow chart
• 5. On-site confirmation of flow chart
• 6. Conduct a hazard analysis (Principle 1)
• 7. Determine the critical control points (CCPs)
  (Principle 2)
• 8. Establish critical limits for each CCP
  (Principle 3)
• 9. Establish monitoring systems for each CCP
  (Principle 4)
• 10. Establish corrective actions (Principle 5)
• 11. Establish verification procedures (Principle
  6)
• 12. Establish documentation and record keeping
  (Principle 7)
• Support programs

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Acceptance of a Food safety Program

• It is one thing to have a FSP and another to make
  it achieve the desired outcome.
• The FSP will set out what has to be done to
  prevent effect of food hazards
• How to do it
• How to train staff
• How to keep records so u can prove the FSP has
  been followed.
• The hardest thing is to achieve behavior
  modification

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Behavior Modification

• It is important that workers feel they have
  ownership of the FSP then they are more likely to
  believe in its value and follow the procedures
• Having staff involved in a HACCP team
• Use existing SOPs as much as possible
• Involve a variety staff in reviews and
  inspections
• Give feedback to suggestions made by staff and
  HACCP committee

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What about existing documentation?

• If it works Dont Fix it
• Some catering and retail operations have been
  following either formal or informal food safety
  programs to varying degrees for some time. There
  is no need for FSP to change or duplicate
  existing documentation.
• More chance of acceptance of the FSP if it
  incorporates existing procedures
• You may alter existing documents to meet the new
  requirements.
• Better acceptance if there is less change in
  staff procedures.
• If information that is already available in
  another systems like HR , there is no need for it
  to be duplicated.
• For example, if you need to develop a list of
  staff and their food handling duties, you can
  reference existing job or position descriptions,
  work orders or other similar documents.

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Support Programs included

• Examples of support programs include
• Illness policy
• Cleaning and sanitizing procedures
• Garbage removal
• Pest control
• Equipment selection
• Employee hygiene.

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Support Programs
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1. Food Safety Policy

• Mission statement
• This statement must list the need for high
  standards of hygiene .
• confirm the commitment that the company has to
  ensure that hygiene is a priority.
• The points to be included are
• clear company statement of quality
• acceptance of aims of legislation
• requirements of company staff and food suppliers
• companys aim to operate the business with all
  due diligence

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1.1 Scope and Purpose

• The scope and purpose of the HACCP food safety
  program should be defined.
• The scope is a statement outlining the products
  and processes covered by the HACCP plan and the
  parts of the operations it covers (the start and
  end point).
• The scope of the plan is important, as it is a
  reference point for many of the following steps
  involved in developing other HACCP plans in the
  business.
• The purpose of the food safety program should
  also be defined. The purpose is a statement of
  the reason the program has been put into
  practice.
• For example to ensure food safety and to enhance
  quality.

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2. Provide info. about the Firm
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3. Assemble the HACCP Team

• The HACCP team, responsible for developing and
  maintaining this food safety plan, must be
  identified.
• Where possible, this should be a
  multidisciplinary team using expertise from
  various groups within the site(s).
• Team Constitution and Procedures need to be
  developed
• Who take minutes
• What happens to minutes
• What constitutes a quorum
• How many meeting can a member miss etc.

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3. The HACCP Team

• A HACCP team should ideally consist of between
  three to seven people all with some knowledge of
  the food-related operations within the business
  and/or knowledge of the food safety hazards
  associated with the product.
• The HACCP team leader is usually nominated.

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3. The HACCP Team
NAME POSITION IN COMPANY
TEAM LEADER
TEAM MEMBER
TEAM MEMBER
TEAM MEMBER
TEAM MEMBER
TEAM MEMBER
TEAM MEMBER
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4. Product Description

• The products covered by the program and their
  intended use must be defined.
• The product(s) should be described and the
  intended use(s) outlined as these assist in
  determining what hazards are associated with your
  product by describing the nature of the product.
• Most businesses will need to state here if the
  product is to be cooked prior to consumption by
  the consumer, further processed by another
  business and/or served without any further
  processing.

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4. Product Specifications may include the
following information

• Product name (e.g. name used on the product)
• Ingredients used
• Form in which the product is sold (e.g.
  fresh/frozen/shelf-stable)
• Type of primary and secondary packaging (e.g.
  primary packaging in contact with product,
  secondary outer pack)
• Preservation methods (if any)
• Shelf life
• Storage and transport conditions required for the
  product
• Labelling (e.g. noting of any known allergens if
  required)

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Product Description
Product Name
Ingredients used/composition
Form
Packaging
Shelf Life
Storage and Transport
Intended Use
Consumer
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5.Intended Use of Product

• It is also important to consider who will eat the
  food.
• If the business sells its product to the general
  public, then it could be expected that the
  product would be consumed by anyone. If it sells
  directly to at-risk groups, then this should be
  stated in the intended use.
• The intended use by the consumer (e.g. indicate
  if the food is ready-to-eat or requires further
  processing)
• The consumers of the product (e.g. general
  population or specific group, such as a
  vulnerable population)

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6. Process Flow Chart

• The purpose of a process flow chart is to provide
  a simple, clear description of the steps involved
  in your process, ensuring that all processes
  mentioned in your scope are covered.
• You may choose to draw a process flow chart for
  each product you produce or group products which
  use a similar process.
• For example a food premises may have a separate
  process flow chart for a beef stew and a curry
  beef OR they may wish to group these and call
  their process flow chart Process Flow Chart
  for Wet Sauce Dishes.
• The flow chart you develop should include all
  steps the product goes through while under your
  control, and in order of operation.
• It should also include any inputs into the
  process including ice, salt, food ingredients and
  chemicals etc. The use of symbols (for operation,
  storage, transport etc. is optional.

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6. Activities shown on Flow chart
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6.Process Flow Chart
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6.Process Flow Chart
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6.Walk through the Flow Chart

• It is important that the flow chart(s) are
  correct and complete as they are the basis for
  the hazard analysis.
• The HACCP team should take the flow chart to the
  area(s) where the food is handled and follow
  through the operations using the flow chart to
  ensure it shows that the same process is actually
  happening.
• If the process is different to what has been
  documented in the flow chart, then the flow chart
  should be corrected to reflect actual process.
• You may find it useful to ask someone in the
  business that hasnt been involved in drawing the
  flow chart to check the diagram.
• Often a fresh set of eyes will see things
  overlooked by those more closely involved in the
  process.

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6. Hazard Analysis

• All potential hazards that may occur at each step
  outlined in the flow chart must be identified.
• When deciding what hazards may occur,
  consideration should be given to
• the process that is occurring
• the particular properties of the product
• any other raw materials added
• equipment in contact with the food
• amount of contact by food handlers and
• packaging or storage containers.
• When identifying the hazards, only consider what
  is happening at
• that step. If other food substances are added,
  hazards related
• with these ingredients would also need to be
  identified

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What is a hazard?

• A hazard is a biological, chemical or physical
  agent, or condition of food with the potential to
  cause an adverse health affect.
• Typical hazards include
• Growth of food poisoning microorganisms
  (pathogens)
• Microbial or physical contamination from food
  handlers
• Microbial or physical contamination from
  equipment
• Survival of food poisoning microorganisms
• Use decision tree to identify CCPs

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Control measures

• Once a hazard has been identified, the next step
  is to consider what control measure(s) can be
  used for each hazard.
• Control measures (also referred to as
  preventative measures) are anything that will
  prevent, eliminate or reduce the hazard from
  occurring.
• In some cases effective support programs are
  sufficient to control a hazard (e.g. a cleaning
  and sanitation program) and so these can be
  documented as the control measure.
• In other cases, specific activities other than
  support programs are required to control a
  hazard, these are referred to as critical control
  points
• More than one control measure may be used to
  control a hazard, and a control measure may be
  used for more than one hazard.

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2.5.1 Determine Critical Control Points

• As part of the hazard analysis,
• CCPs must be identified.
• CCPs are defined as a step at which control can
  be applied and is essential to prevent or
  eliminate a food safety hazard or reduce it to an
  acceptable level.
• Determining if a CCP is needed can be achieved by
  using the CCP decision tree

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The CCP Decision Tree

• The decision tree is a series of questions that
  should be asked for each hazard at each step to
  determine if a CCP is required at that step.
• It would be expected that different types of
  businesses will have different CCPs, although
  generally speaking CCPs would include cooking,
  storage and transportation steps for ready-to-eat
  products.
• Sometimes, the CCP Decision Tree will identify a
  hazard as a CCP, but if an effective support
  program has been put in place (eg Cleaning and
  Sanitation Program) then the CCP can be
  classified as a support program instead.

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Risk Analysis
Accept
Reject
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Acceptable Risk

• If a risk cannot be controlled other than trying
  to purchase safe raw material you need to assess
  the risk
• To assess the risk there are three factors to
  consider
• How often is the food consumed
• What is likelihood that an illness will develop
• Chance that food in contaminated
• Pathogenistity of disease causing agent
• What is the consequence of illness
• How severe are the symptoms

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2.6 Hazard Audit Table

• The Hazard Audit Table is used to determine how
  you will control each of your Critical Control
  Points. For each CCP you will need to establish
  and document
• The critical limit
• How you will monitor it
• What to do if you exceed the critical limit and
• How you will record you CCP results. Note All
  CCPs will need to be recorded.

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Hazard Audit Table
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Establish Critical Limits

• Once a business has identified its CCPs, it must
  determine at what point the product may become
  unsafe at that particular step in the process.
• Numerical values must include units and maximum,
  minimum or acceptable range of values.
• Critical limits usually refer to a parameter that
  can be checked while the step is occurring (e.g..
  time) so that if the limit is exceeded, effective
  corrective action can be taken immediately to
  correct the process and to prevent the unsafe
  product from reaching the consumer. For this
  reason, microbiological testing is usually not a
  critical limit, as results may not be available
  before the product has been passed on to the
  buyer and possibly consumed by the customer.
• Therefore hazards that relate to food poisoning
  micro-organisms are typically controlled by
  effective temperature control and/or control of
  chemical parameters of the food (eg pH and salt).
  Examples of typical critical limits include
• Temperature and time parameters for cooking
• Temperature for storage and transportation
• Chemical testing such as pH and salt measurements
• Physical checks such as the presence of foreign
  objects

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Establish Critical Limits

• If you are unsure of what the critical limit for
  the CCP will be you may refer to
• Information from the Industry Guide,
• Industry Codes of Practice,
• Regulatory requirements or
• Published scientific information such as
  recognised scientific papers or literature.
• In addition, some businesses may find it
  worthwhile obtaining external assistance

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Assessment of Control measures

• Validation (Justification) of Critical Limits.
• It is important to remember that the critical
  limit must control the hazards.
• Unless the critical limit is a commonly accepted
  limit, such as the storage temperature of foods
  in accordance with the Food Standards Code,
  businesses will need to show proof that the
  critical limit will differentiate between safe
  and unsafe food.
• This will usually involve having some documented
  information outlining the source reference, or a
  validation study showing data, to justify each
  critical limit. A table summarising the
  justification for each CCP is recommended.TBC

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Establish Monitoring Procedures

• Once the critical limits have been determined,
  requirements for measuring against the critical
  limit needs to be established (eg monitoring
  procedure). The monitoring procedures must state
• What is to be monitored
• When the monitoring will occur (frequency)
• Who performs the monitoring and
• How it will be monitored.

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FOOD SAFETY SUPPORT PROGRAMS

• PURCHASING AND RECEIPT OF FOOD
• TRAINING PLAN
• CLEANING AND SANITATION PROGRAM
• OTHERS

Terms, Conditions and Standards for Food Supply Guidelines for Perishable Food Delivery Temperatures LETTTERS AND DOCUMENTS FOR SUPPLIERS SUPPLIER QUESTIONAIRE (MIKE TO SUPPLY COPY Flow Chart of Receival of Goods Central Stores
Training Agreement Training Matrix Assessment for Food Service Staff Training Compliance Food Handling Staff Assessment Checklist
Tea-towels and wash cloths Dishwashing Garbage Floors Water
4. MAINTENANCE PROGRAM 5.CALIBRATION 6.WASTE MANAGEMENT 7.PEST CONTROL 8. DOCUMENT CONTROL 9.PRODUCT RECALL PROCEDURES Food Recall Notification Form 10.CUSTOMER COMPLAINTS PROCEDURES Customer Complaint Form..
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PURCHASING AND RECEIPT OF FOOD

• All goods purchased are delivered from approved
  suppliers, under the specified conditions stated
  in the Victorian Food Act.
• Letters are to be sent out to each of the
  suppliers with a copy of the Terms and Conditions
  for supplying goods.
• Records of these suppliers are retained in the
  Central Store Managers Office.
• Goods not meeting the required specifications
  will be rejected.
• A follow up phone call and letter will be sent to
  the offending companys representative.
• Good left unattended on the loading dock will not
  be accepted and the supplier will be required to
  collect such items at the time of replacement.

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Terms, Conditions and Standards for Food Supply

• All food items ordered must be of premium
  freshness and quality
• All foods supplied must conform with the "Food
  Act 1984", "The Australian New Zealand Food
  Standard Code" or any other relevant codes
• All Food items must be clearly labelled and
  display Use By and Best Before Codes on each
  individual product
• Delivery of out of date or close to out of date
  product will not be accepted
• Products that have damaged packaging or that are
  inadequately labelled will not be accepted.

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Food Transport Deliveries

• All food items are to be delivered via an
  approved Food Transport Vehicle clearly
  designated for food transport
• Refrigerated food must be delivered in a
  refrigerated vehicle which is maintained at 5C
  or below
• Vehicles delivering fresh fish/seafood/shellfish
  must be maintained at 2C. or below, but not
  freezing the products
• All refrigerated and frozen food is to be packed
  in the vehicle in a manner that allows the
  circulation of air around the outer surrounds of
  the outer most containers of the mass
• Frozen foods must be delivered in a vehicle
  which is maintained at -18C

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Supplier Questionaire

• COMPANY NAME -------------------------------------
  ---------------------------------------------
• CONTACT NAME--------------------------------------
  --------------------------------------------
• TITLE---------------------------------------------
  --------------------------------------------------
  --
• DATE----------------------------------------------
  --------------------------------------------------
  ----
• 1. Are you currently certified or working towards
  a Quality Assurance Management
• System or Food Safety Plan?
• 2. Is it a H.A.C.C.P. based system?
• 3. Are your products produced according to the
  specifications under the
• Victorian Food Act?
• 4. What preventative processes do you have in
  place to control food poisoning?
• 5. Do you have an action plan in place if
  supplies are incorrectly delivered?
• 6. Are your production and delivery staff trained
  in food handling and personal
• hygiene practices?
• 7. Are your suppliers approved businesses with
  Quality Assurance programs or
• H.A.C.C.P. based Food Safety Plans?
• 8. Would you object to a representative from our
  company visiting your site?
• 9. Would you object to a representative from our
  company inspecting your vehicle
• on delivery of food to our site?

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TRAINING PLAN

• All staff are expected to attend courses in food
  hygiene and handling, and as a minimum obtained a
  Food Handling Certificate or equivalent
  qualification.
• Team Leaders, managers and Food Safety
  Supervisors are expected to have obtained a
  current Food Safety Supervisors Certificate. This
  certificate must remain with 3 years of currency.
• Records of training are kept maintained in the
  Human Resources Department.
• Site Managers are to arrange orientation of new
  staff, agency staff of casual staff.

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Training Matrix
Leaders
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Teachers or Food Handling Staff Assessment
Checklist
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CLEANING AND SANITATION PROGRAM

• All equipment will be cleaned and sanitised at
  the end of sessions or more often if required.
• All Standard Operating Procedures (SOPS)
  concerning cleaning and sanitising will be
  strictly adhered to.
• Dust is to be removed from all surfaces.
• The cleaning program is checked on a daily basis
  by the Food Service Assistants and contract
  cleaners.
• Mops and buckets are removed from the kitchens
  after use and are colour coded to avoid
  accidental use in non kitchen areas.

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Garbage

• Refuse is removed at the end of each session or
  meal service. At the end of the day, the bins are
  washed.
• All rubbish is transported to a dump master,
  which is under a contract for regular removal.
• Recycling standards are strictly adhered to.
• The cleaning routines for rubbish bins are
  monitored and recorded daily on cleaning
  schedules.
• Cleaning staff adhere to good hygiene practices
  after rubbish disposal.
• Any waste will be disposed of into clearly
  identified containers and kept away from areas
  where materials and in process product may become
  contaminated.

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MAINTENANCE PROGRAM

• All equipment, walls, plumbing and fittings are
  maintained in good condition to avoid the risk of
  pests entering or foreign objects adulterating
  foods.
• A maintenance program is carried out and
  documented. (refer to maintenance schedule)
• Any waste from mechanical or electrical work on
  any equipment is to be completely removed from
  the area, by the person doing the work, when a
  break is taken or work completed.
• All pieces that are removed from equipment
  (screws, bolts, nuts, plates, brackets, wires,
  etc) are to be placed in a secure place.

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CALIBRATION

• Calibration is carried out every 6 months to
  check that temperatures are correct on
• Fridges/Freezers
• Coolroom
• Ovens/Microwave units
• Bain Marie ( other hot holding units)
• Dishwasher Glass wash temperatures
• Temperature probes/Scales

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PEST CONTROL

• Authorised and registered pest exterminators are
  contracted to control the preventative pest
  maintenance system.
• Controls are in place throughout the facility and
  building surrounds.
• Records of site inspections and pest sightings
  are documented and held at the front reception
  desk
• The frequency of the contractors on-site
  inspections is monthly.
• The bait must be laid where there is no risk of
  contamination of food, utensils, equipment or
  humans.

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PRODUCT RECALL PROCEDURES

• If a Staff member or Student identifies a likely
  health risk to food
• Or A customer complaint is received about the
  safety of food
• Notify (Manager Food Processing Programs) Then
• Stop distribution of affected product
• Assess the risk to health
• Three possible courses of action
• Do nothing
• Withdraw product
• Recall Product

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Food Recall Notification Form

• COMPLETE AND FAX THIS FORM TO THE HEALTH
  DEPARTMENT
• Date .............................................
  ..................................................
  ..................
• Company...........................................
  ..................................................
  ..............
• Contact...........................................
  ..................................................
  .................
• Address...........................................
  ..................................................
  ................
• ..................................................
  ..................................................
  ......................
• Telephone .......................................
  Fax ..............................................
  .....
• Person Responsible ...............................
  ..................................................
  ........
• Food Type ........................................
  ..................................................
  ..............
• Quantity of product affected......................
  ..................................................
  .......
• Brand Name .......................................
  ..................................................
  .............
• Product Size .....................................
  ..................................................
  ..............
• Date marking/Batch Code...........................
  ..................................................
  .....
• Nature of Hazards ................................
  ..................................................
  ..........
• Has any testing been done? YES NO
• If yes, result....................................
  ..................................................
  .................
• LEVEL OF RECALL
• Student Supplier General Public Staff Member
• ACTION PROPOSED AND ACTION TAKEN..................
  ...................................

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Dishwashing

• Pots, utensils and equipment are washed in a
  commercial dishwasher using the
• recommended chemicals.
• The dishwasher temperatures are visually checked
  daily by the food service assistants and
  monitored on daily record.
• Maintenance is notified immediately if the
  temperatures are incorrect.
• Equipment and utensils are air dried where
  possible. The use of cloth for drying is
  discouraged.
• All items are dried prior to storage.
• Disposable gloves are to be changed between
  handling soiled dishes/equipment, waste
• and between removing/storing washed dishes and
  equipment.
• Chemicals are stored separately and correctly in
  labelled chemical containers away
• from the food storage and food preparation areas.

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Support Programs

• Document Control
• Headers for all pages
• Format for a Header on all pages of FSP
• Format for a Header on all pages of each record
  sheet
• Name of facility ________________________________
  ________________page .......... of ..........
• FSP /Rsheet Number ________ Title
  _________________________________________________
• Revision number ________
• Written by ______________________________ Edited
  by __________________________
• Authorization signature ________________________
  Department _______ Date ___________
• Effective date ___________________________________
  _ Replaces ____________________
•  

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Document Control

• Any change to the FSP or a record sheet must be
  recorded.
• There must be Procedure for changing FSP and
  record sheets an SOP
• Any requested variation must be circulated to all
  committee members
• If approve at a FS committee meeting only
  authorside person can actually change FSP and it
  get a new version number
• All changes must be kept on file and a central
  register of changes maintained

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Validation of processes

• Validation of processes may consist of a number
  of components
• Reference to industry guidelines and Codes of
  Practice e.g. accepted time temperature
  parameters for cooking.
• Reference to regulated standards e.g. compliance
  to the Food Standards Code.
• Intensive product testing may be used to validate
  a change to a process.
• Environmental testing may be used to validate the
  effectiveness of a cleaning system.

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Examples of monitoring procedures

• Examples of monitoring procedures include
• Temperature checks
• Measuring the chlorine concentration in water
• Measuring the pH of a food
• Measuring the salt concentration
• The data collected must be recorded accurately
  (eg on a recording form refer to Form 2 of the
  template) as per Section kept on file at all
  times.

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Establish Corrective Actions

• The corrective action procedure should state
• How to bring the process back under control
• What to do with product produced while the
  process was not controlled and
• Who is responsible for the corrective action?
• Product produced while the process was not under
  control should either be reworked/reprocessed or
  rejected.
• Reworking or reprocessing the product should only
  occur if the business can assure that the
  hazard(s) can be eliminated or reduced to a safe
  level.
• A record of the corrective action(s) taken must
  be maintained.

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Implement the food safety Program

• Once you have a Food Safety Program, you will
  need to implement all the
• instructions and use it in your business to help
  improve your food safety.
• This means that you have to follow all the
  applicable points on the hazard pages and support
  programs and write some things down on the record
  sheets.
• In this book, there are forms which you can
  photocopy and use to keep your records.
• Put these records in the same folder as your Food
  Safety Program otherwise you can develop your own
  records as long as they contain the information
  required by this template.
• Your Food Safety Program needs to be reviewed
  regularly so that it reflects the activities and
  processes of your business. If there are any
  changes in your business processes that change
  your template youll need to tell your local
  Council

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Primesafe

• If your business sells, transports or prepares
  mainly meat (like a butcher) or seafood (like a
  fishmonger) then you should be registered with
  Primesafe (they can be contacted on 9685 7333).

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Dairy Food SafetyVictoria

• If your business sells, makes, transports or
  prepares mainly dairy products (like a dairy or
  cheesemaker), then you should be registered with
  Dairy Food Safety Victoria
• (they can be contacted on 9810 5900 or at their
  website www.dairysafe.vic.gov.au).

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Mixed Premises

• However, if you run a butchers operation within a
  mixed premises, e.g. A supermarket, you still
  need to registered with your local Council under
  the Food Act,
• but you will need to read and comply with the
  Victorian Standard for the Hygienic Production of
  Meat at Retail Premises (November 1988) which you
  can get from Primesafe
• (they can be contacted on 9685 7333).