Introduction to Fssc 22000
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Introduction to FSSC 22000
6/13/2013
INTRODUCTION TO FSSC 22000
FOOD SAFETY MANAGEMENT SYSTEM By Jacqueline Toon SQC Management Sdn Bhd
COURSE CONTENT SECTION
1: BACKGROUND OF FSSC 22000
SECTION
2: BACKGROUND OF ISO 22000
SECTION
3: TERMS & DEFINITIONS
SECTION
4: ISO 22000 REQUIREMENTS
FOODBORNE INCIDENTS According to the Centers for Disease Control and Prevention, Atlanta, foodborne illness affects an estimated 48 million people in the United States every year. Of those, 128,000 are hospitalized and around 3,000 die.
SECTION 1: BACKGROUND OF FSSC 22000
Source: http://www.foodsafetymagazine.com/fsm-edigest/foodsafety-focus-on-packaging/ , June 4, 2013
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Introduction to FSSC 22000
Key Food Safety Issues
Existing Issues Being addressed
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Key Food Safety Issues
New Issues beginning to be addressed
Hygiene of eating establishment Residue of veterinary drugs Pesticides Abuse and overuse of food additives Mycotoxin inorganic contaminants
Effort already taking place to reduce the contravention and risk to consumers.
Food Packaging Safety Quotes … “If you supply a food company, you are no longer just the packaging industry, you are a part of the food industry”
Migration of chemicals substances from packaging materials and other materials in contact with food Persistent Organic Environmental Pollutants (dioxin, PCBs, PAH) Chemical substances formed during cooking/processing Hypersensitivity, intolerance and allergic reactions Antibiotic resistant microorganism
What is FSSC 22000 A set of requirements for a Food Safety Management System (FSMS) It was developed to fill the need for a worldwide Food Safety Standard
“We treat food packaging with the same food safety rigor as food ingredients.”
(Ms. Wade-Kudla senior manager of packaging at General Mills I nc., Minneapolis)
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Introduction to FSSC 22000
WHY FSSC 22000? There have been an abundance of food safety standards in use, the problem was that they were not equivalent. It was hard to know what each certification really meant.
Global Food Safety Initiative (GFSI)
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If your customers want to see a GFSI recognized certification …
you will need to use FSSC 22000, ISO 22000 is not recognized.
GFSI determine that the prerequisite programs requirements in ISO 22000 were not specific enough!!
How the GFSI requirements are covered in the key global food safety standards:
A food retail initiative created in May 2000 by the Global Food Business Forum (CIES) A network of 175 retailers and 175 suppliers in over 150 countries, representing 65 percent of global food retail revenue.
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Introduction to FSSC 22000
SCOPE OF FSSC 22000
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THE ORIGINS OF A GLOBAL STANDARD
Applies to Food manufacturers or food packaging manufacturers
Uses ISO 22000 for the food safety management system requirements
Uses an additional document for prerequisite requirements
Food Manufacturers/Processors - ISO/TS 22002-1 (supersedes PAS 220: 2008)
Food Packaging Manufacturers - PAS 223
WHY FSSC 22000 WORKS?
Integrates food safety management easily with other management systems, such as quality, env ironmental and safety management systems;
Fully incorporates ISO 22000:2005, PAS 220:2008 Pre-requisite Programmes (PRPs), HACCP, and the application steps of CODEX;
Is fully recognised by the Global Food Safety Initiativ e (GFSI);
Controls/reduces food safety hazards and promotes continuous improv ement on Food Safety Aspects;
SECTION 2:
Fosters legal compliance;
BACKGROUND OF ISO 22000
Increases transparency throughout the food supply chain; and
Allows small and/or less dev eloped organisations to implement an externally dev eloped system.
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Introduction to FSSC 22000
ISO 22000 throughout the food chain
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What is ISO 22000? Food Safety Management Systems Requirements for any organization in the food chain. ISO Technical Committee 34 Working Group 8 (ISO TC 34/ WG 8) Also members: Global Food Safety Initiative (CIES) Codex Alimentarius CIAA
Why ISO 22000? Problems in food supply chains Needs for harmonization Integration Food Safety in management systems (ISO 9001, ISO 14001 etc)
Characteristics of ISO 22000 Food Safety Management System standard Apply to all suppliers within the food supply chain Requirements for internal & external communications Food safety hazards: controlled by CCPs & Operational PRPs Reference: List of specific code of practices
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TERMS AND DEFINITIONS Food Safety Concept that food will not cause harm to
the consumer when it is prepared and/or eaten according to its intended use
SECTION 3:
Food Safety Biological, chemical or physical agent in food, or condition of food, with the Hazard
TERMS & DEFINITIONS
Control Measure
TERMS AND DEFINITIONS Operational PRP
Critical Control Point (CCP)
PRP identified by the hazard analysis as essential in order to control the likelihood of introducing food safety hazards to and/or the contamination or proliferation of food safety hazards in the product(s) or in the processing environment 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
potential to cause an adverse health effect action or activity that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level
TERMS AND DEFINITIONS Critical Limit Criterion which separates acceptability from unacceptability
Monitoring
Correction Corrective Action
Conducting a planned sequence of observations or measurements to assess whether control measures are operating as intended Action to eliminate a detected nonconformity Action to eliminate the cause of a detected nonconformity or other undesirable situation
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Introduction to FSSC 22000
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Validation
obtaining evidence that the control measures managed by the HACCP plan and by the operational PRPs are capable of being effective
Verification
Confirmation, through the provision of objective evidence, that specified requirements have been fulfilled
Regulatory authorities
TERMS AND DEFINITIONS
Feed producers
Producers of ingredients
Primary food producers
Producers of equipment
Food processors
Producers of cleaning agents
Transport and storage operators
Distributors Retailers
Producers of packaging materials
Services providers
Others
Consumer Figure 1 : Communication along the food chain
Components of Food Safety Management System
Outline of ISO 22000? Sections 4 - 8 Contain the requirements ISO 22000 Standard Section 1: Scope Section 2: Normative Reference Section 3: Terms & Definitions Section 4: General Requirements Section 5: Management Responsibility Section 6: Resource Management Section 7: Planning & Realization of Safe Products Section 8: Validation, Verification & Improvement
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Introduction to FSSC 22000
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4.1 General Establish an effective Food Safety Management System (FSMS) Keep it current Identify outsourced processes
SECTION 4: ISO 22000 REQUIREMENTS
4.2 Documentation Requirements Document your system Control your documents
4.2 Records Maintain required records Control your records
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Introduction to FSSC 22000
5.1 Management Commitment
Management must be involved in and committed to the FSMS.
Objectives support safety Everyone knows the importance of meeting the requirements
5.3 FSMS Planning
As top management, take an active role in planning the system
Be involved in the design and implementation Make sure the integrity is maintained as changes are made
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5.2 Food Safety Policy Management creates for Food Safety Policy Management is responsible for communicating the policy Management is responsible for ensuring that the policy is implemented
5.4 Responsibility and Authority Define responsibilities and authority Communicate them Everyone is responsible for reporting problems with the FSMS - make sure they know that
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Introduction to FSSC 22000
5.5 Food Safety Team Leader
Appointed by top management Reports to top management on the status of the FSMS
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5.6 Communication
Establish a system for external communication
Establish a system for internal communication
5.7 Emergency Preparedness Be prepared to respond to emergency situations Prepare an emergency plan to address potential situations:
Suppliers, contractors, customers, SR&R authorities, external expert
Food safety team meeting
5.8 Management Review Key step in a Management Systems Approach Management meets to evaluate the performance of the FSMS
Fire Flood Accidents Contamination Others...
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Introduction to FSSC 22000
6 Resource Management
Top management is responsible for providing the resources required Human resources Infrastructure Pre-requisite Programme Work Environment
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7 Planning & Realization of Safe Product
Your organization will need to plan all of the processes that go into making your product in order to ensure a safe end product
7.2 Prerequisite Program
Basic Conditions and activities that are necessary to maintain a hygienic environment throughout the food chain
The Food safety Team establishes PRPs For FSSC 22000 you will also include prerequisite programs to meet the requirements of PAS 223
PRP OPRP HACCP
7.3 Preliminary Steps
The Food Safety Team
Identifies product characteristics Describe intended use Prepare flow diagrams Describe process steps and control measures
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Introduction to FSSC 22000
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7 core principle steps of HACCP
The HACCP system is implemented as described above which includes five preparatory steps and seven principle steps.
7.4 Hazard Analysis
The Food Safety Team
Hazard Analysis Critical control point
Critical Limits
Verifies the accuracy of the flow diagrams Conducts hazard analysis to identify potential food safety hazards Selects control measures to prevent or eliminate those hazards
M onitoringand sampling Corrective Action Verification Documentation
FOOD SAFETY HAZARDS & CONTROL
Types of Hazards Biological
Physical
Chemical
BIOLOGICAL HAZARD Bacillus cereus Campylobact er jejuni Clost ridium bot ulinum Clost ridium perfringens Escherichia coli List eria Monocyt ogenes Salmonella species Shigella dysent eriae St aphylococcus aureus Vibrio cholerae Yersinia ent e
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Introduction to FSSC 22000
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FACTORS AFFECTING MICROBIAL GROWTH
PHYSICAL HAZARDS
Food
Acidity)
Preservative
Temperature
Moisture
Oxygen
CHEMICAL HAZARDS
Naturally occurred mushroom, some fish species, some tapioca species, allergen
Commercially added pesticides, herbicides, colouring, additives
Unintentionally added cleaning agents, sanitizers, lubricants
Hair, feather Pest & their droppings metal fragment , glass Sand, wood, stone peeled off paint jewelry, buttons cigarette butts band aid, pen caps rubber band, plastic pieces
Time
Food Hazard Assessment Risk is to be calculated for each hazard and a risk rating sheet can be dev eloped as described below :
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Introduction to FSSC 22000
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Food Safety Risk Matrix
CCP Decision Tree
Value of 15 – 25 (red area): High Risk, control measure is essential, determined by Decision Tree Value of1– 12 (green area): Low Risk, Up to the HACCP team to decide whether it makes sense to hav e the control measures
RAW MATERIAL CCP DECISION TREE Q1
Is there a hazard with this raw material? NO
Go to next raw material
Are you or the customer going to process this hazard out of the product?
CCP
Q2 Is the step specifically designed to eliminate or reduce the likely occurrence of a hazard to an acceptable level?
Not a CCP NO
Q3 Could contamination occur at unacceptable level(s) or increase to an unacceptable level? Not a CCP NO (Ctrl by OPRP) YES Q4 Will a subsequent process step eliminate or reduce the hazard to an acceptable level?
YES
CCP
Is control necessary at this step for safety? NO
Not a CCP (Ctrl by OPRP)
NO
YES
Is there a cross contamination risk to the facility or to other products whic h will not be controlled?
YES NO
YES
NO
Q3
Modify step, process or product)
Q1 Are there preventive measure(s) for the identified hazard?
Not a CCP
YES
Q2
PROCESS STEP CCP DECISION TREE
Go to next raw material
YES
Not a CCP (Ctrl by OPRP)
Next process step
YES
Next process step
NO
CCP Next process step
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Introduction to FSSC 22000
7.5 Establish Operational PRPs
Similar to a Critical Control Point, an Operational Prerequisite Program is a control point where biological, physical, or chemical hazards identified in hazard analysis can be controlled. Your food safety team will determine if the control point is a CCP or oPRP using the decision criteria in Section 7 of the standard. The Food Safety Team establishes Operational PRPs
7.7 Updating
Updates any preliminary information that may have changed during or as a result of the hazard analysis
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7.6 Establish the HACCP Plan
Documents the HACCP plan
7.8 Verification Planning Identify what verification activities are required including verification of PRPs, the HACCP Plan and other procedures. Verification will include internal audits, any food safety or GMP audits, verification of cleaning records and HACCP records and other activities that you identify for your system.
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Introduction to FSSC 22000
7.9 Traceability
A traceability system ensures that the identification of product is maintained from raw material to delivery.
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7.10 Control of Nonconformity
Establish the traceability of product From supplier to distribution
When a control limit is exceeded or an OPRP is found to be out of control affected product must be controlled.
7.10.4 Withdrawal
To have complete & timely withdrawal of lots of end products
Corrections Corrective actions Handling of potentially unsafe product
8.2 Validation, & 8.3 Control of Measuring & Monitoring All measuring equipment must be capable of the required measurements and show calibration to national or international standards. Calibrate and control measuring equipment to ensure that measurements are valid
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Introduction to FSSC 22000
8.4 Verification Establish and document an internal audit process The Food Safety Team evaluates and analyzes verification results The Food Safety Team takes any necessary action
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8.5 Improvement
Continually improve the FSMS through the use of:
8.5 Updating the FSMS Top management is responsible for seeing that the FSMS is continually updated The Food Safety Management Team evaluates the FSMS at planned intervals
Management review Internal audits Corrective actions Verification results Validation results
THANK YOU FOR YOUR ATTENTION
QUESTIONS ? 17
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