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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Introduction to FSSC 22000

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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



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