Hazard Analysis Critical Control Point Training

Hazard Analysis Critical Control Point Training
HACCP Hazard Analysis Critical Control Point Training Level 2: Understanding January 2017 Morning/afternoon Introduce self (and other trainer if relevant) Start with housekeeping – fire exits, catering arrangements, toilet facilities and mobile phone ‘rules’ Ask delegates to say briefly The company you are from What the products are What you would like to get out of the course – (delegates should have thought about this because the ‘joining’ letter asked them to come with their personal requirements) What level of food safety training have you done before? This course has been developed because it has been acknowledged that when a small to medium sized company (especially) wants to increase their understanding or implement HACCP they go on a course – a generic course not particularly related to their products – they then return to their company and they still are not sure where to start. Also that jargon confuses people. Our aims therefore are to work with you to ensure that you leave at the end of the day feeling confident that you understand HACCP, how it’s applied and with the skeleton or part of a HACCP Plan for your business. We’ll undertake to To avoid jargon wherever possible – sorry the first slide has two acronyms!!!! I have put the full words up for you. READ OUT Explain any words or concepts that you do not understand so please tell us if you’d like further explanation To explain the necessary jargon so that we are all speaking the same language. We have to use some terminology because it is included in legislation and therefore may be used by enforcement personnel or customer auditors but we want you to feel comfortable with it. 3) To show you that the people who work on the products are the best (only) people to write the HACCP plan for a company and give you the confidence to defend your plan against any challenges from those who do not know as much about your business as you do!.

Today’s session will cover:
Food Safety - what is it and why is it important? How a company can achieve a control system that produces safe food The structure of a food safety system HACCP and its role in the system How to implement HACCP in your company Our plan for the day is to go back to basics and look at food safety as a topic We’ll look at designing a food safety system and what’s involved - it’s more than just HACCP. We’ll look at applying HACCP and identifying hazards so we will work together on looking at some hazards and their prevention and control– looking at all types of hazards but mostly concentrating on the microbiological ones as these are the ones that small businesses can feel least confident about managing Then we will look at some examples of processes to make products, the way they flow and the importance of writing down every step We start by looking at food safety because producing any food involves some risk – it something goes wrong you could kill somebody or at least make them very ill. The consequences of the food safety system going wrong can be disastrous – for all concerned - we’ll consider this during the course. Taking a logical and thorough approach can help prevent problems so, simply, prevention is always better than cure!

When you see a dark purple screen that’s your chance to get involved!
Course Assessment Your course result will be a combination of a short multiple choice test and a measure taken of your engagement with today's course and activities. When you see a dark purple screen that’s your chance to get involved! Explain how delegates will be marked

Learning Outcomes for this Course
To know: The purpose of a HACCP system 2. The features of a HACCP system 3. How a HACCP system is applied in the workplace

Why is Food Safety important?
Discussion Why is Food Safety important? So – Why is food safety important? Trainer – Use flipchart to collect ideas from the group and then sort them under the following categories: Protecting the Consumer Protecting your Business Compliance with legislation Use the next slide to summarise Tell us what you think!

So who is responsible for Food Safety in YOUR business?
Why is Food Safety important? To protect the consumer To protect your business To comply with the law So who is responsible for Food Safety in YOUR business? Summarise and ask who is responsible for food safety within a business? Confirm on the next slide the answer is ‘Everyone’ but in different respects – discuss with the group the different roles of various personnel – owners/managers, supervisors, operatives

So who is responsible for Food Safety in YOUR business?
Why is Food Safety important? To protect the consumer To protect your business To comply with the law So who is responsible for Food Safety in YOUR business? EVERYONE! Confirm the answer is ‘Everyone’ but in different respects – discuss with the group the different roles of various personnel – owners/managers, supervisors, operatives

What Happens when Food Safety Control fails?

What are the Food Safety laws?
There are two main pieces of law covering food safety – one is the Act of Parliament for the UK and the other are the European Regulations on the Hygiene of Foodstuffs What does the law say? Trainer use flipchart to collect ideas to provide details, then summarise: See next slide

What are the Food Safety laws?
The Food Safety Act 1990 EC 852/2004 Regulation on the Hygiene of Foodstuffs Apply principles of HACCP to hazards specific to business and process Based on risk assessment The Food Safety Act 1990 details main offences – To sell food that is injurious to health To sell food that is unfit or so contaminated that is would be unreasonable to expect it to be eaten To sell food that is not of the nature, substance or quality demanded by the customer EC 852/2004 (European Regulations) requires food businesses to Apply the principles of HACCP to identify and manage food safety issues within their process using a tried and internationally accepted technique that was specifically designed for the purpose Allows a business to design a way of managing food safety that is specific to their business and process only and is based on risk assessment so only the issues relevant to the business, their ingredients, their process and factory, their workforce and their finished products need to be very tightly managed over and above standard industry good practices. EC 852/2004 also describes the specific requirements for food businesses in terms of design of premises, design and finishes in food rooms, equipment requirements, cleaning, pest control, maintenance, personal hygiene etc and applies to all food businesses

What do you think are the Consequences of NOT managing Food Safety?
Discussion What do you think are the Consequences of NOT managing Food Safety? So -What are the consequences of not managing food safety/complying with the law? Trainer to use flipchart to elicit ideas from trainees about what the consequences of failing to manage food safety Customer/consumer illness or injury Customer complaints Major customer scrutiny Loss of business Environmental Health scrutiny Legally required improvement or prohibition (including business closure, job losses) Prosecution Fines Imprisonment Protecting the business Trainer to ask why it is important to protect the business Reputation of the business and of the industry sector Protection of employee’s jobs and livelihood Impact on other related businesses e.g. Cheesemaking operations on dairy farms Trainer to use next slide to summarise

Consequences of a Hazard to the Consumer
Illness or injury/complaints - DEATH Customer and EHO scrutiny Prosecution, fines/imprisonment Loss of business/customers Loss of jobs as production reduced/ Company closes with consequences for the workforce Trainer to explain that the most serious outcome is that consumers are affected – and that some of the outcomes could be devastating for those affected Any hint of a problem and customer and enforcement personnel will focus on the business to try to prevent further issues Enforcement personnel will focus on any business that they feel to be posing a risk – more checks and visits Enforcement personnel have very comprehensive powers to deal with food businesses when they consider that there is potential for a food safety issue – they try to help and educate first but if there is a significant concern or an imminent risk to health, they have a number of legal powers including business closure available to them. Prosecution and penalties may be imposed and will seek to identify and deal with those responsible (may be anyone within the business) Customer scrutiny – more audits, checks, doubts by customer Loss of business – customers look elsewhere when lack of supply – lose confidence which ultimately impacts on those who work within the business and may lose their jobs

Discussion What Makes Food Safe? Ask delegates what makes food safe
Trainer use flipchart to gather delegate’s thoughts Extract –freedom from various forms of contamination – microbiological, chemical, physical, allergenic and obtain some examples Move to next slide to summarise and explain

What makes Food Safe? Freedom from contamination i.e.
Microbiological (Pathogens) Physical Chemical (including Allergens) Making sure Pathogens cannot grow Safe Food is obtained through: Correct and careful processing Protecting the food from further contamination after processing Run through answers and ensure all delegates are comfortable with what each category covers

Back to the beginning… As soon as we harvest food, it starts to deteriorate… So why might we need to preserve food? Explain food in it’s natural state will start to break down as soon as it’s harvested/killed. This caused problems for our forefathers as they needed a supply of food throughout the year for seasonal crops and also, if they killed a large animal, to keep it in edible condition until they were able to consume the whole kill. The deterioration in food as it ‘broke down’ is caused by chemicals naturally present in the food and/or the action of bacteria and other micro-organisms from the soil and surrounding environment. So how did they manage to keep the food? Ask for examples of foods that have been around a long time and have a long shelf life - dried meats – Biltong, Cheese, Cured meats These foods are preserved in different ways i.e. they can be kept for longer. Understanding food preservation is important as we use many of these techniques today in various forms and we rely on getting these techniques right to ensure the food will not only last but will also be safe for consumption Example – home canning of vegetables in the southern states of the US without understanding the important aspects of the process resulted in botulism being relatively common in the 19th century. Paste of Wild Duck at Loch Maree in Scotland in 1922 – all 8 people affected died – also Clostridium botulinum

Common Preservation Techniques
Heating Drying Use of chemicals Chilling/Freezing Adding acids Manipulation of gases around the product Many of these preservation techniques are based on stopping chemical changes in the food and killing or slowing down the growth of micro-organisms/pathogens. The main techniques – Trainer to explain each and the way that these work Heating – killing the growing microorganism – breaks up the bacterial cell - Chilling/Freezing – slowing down or preventing growth (though not killing) Use of Acidity/Pickling – taking away growth conditions/destroying cells – Manipulation of Moisture - Drying – removing enough moisture so no growth Use of Other Ingredients - Use of Salt, Use of Sugar (and effect on moisture within food), nitrites. Change environment away from that pathogens preferred Manipulation of Gaseous Environment – Vacuum Packing, Gas Modification. Change environment away from that which most pathogens prefer (air composition)

ACTIVITIES Handouts 1 and 2
Activity : Refresher on what happens to micro-organisms under different conditions and link to the preservation methods above See handout 1 Activity: Work out what methods of preservation are used for different food products & therefore impact on micro-organisms. See handout 2 You can also discuss which of the techniques discussed have been employed for delegates own products, go through them one at a time while referring to previous slide on the screen Summarise by commenting that it is often a combination of techniques that make the food safe and gives the food it’s shelf life, each needs careful control if the food is going to remain safe e.g. Cheddar cheese - chilling of milk, pasteurisation/heating, use of a starter culture to develop acidity, addition of salt and possibly vacuum packing to prevent mould growth during retailing. Handouts 1 and 2

The Food Chain So what do we do?... Primary Processing Secondary
Retailing/ Catering Agriculture Consumer In the majority of cases, however, there are many ‘links’ in the food chain. Although a gross simplification with no storage and transportation steps, ask delegates where they are on this processing ‘continuum’ Explain that many food products start in agriculture and are processed through initial stages (e.g. flour milling, sugar beet processing, milk/cream pasteurising) before being sold for further processing (e.g. cake manufacture, ice cream) prior to going to the retailer or caterer for sale to the consumer. Or beef burger – Farm → Slaughter →Cut into joints → Remove meat → Mince & Mix – Form burgers → Pack → Cook and serve → Eat So what do we do?...

Potential Contaminants/Hazards in the food chain
Discussion Potential Contaminants/Hazards in the food chain DISCUSSION Redraw the slide details on a flipchart Refer to earlier slide and consideration of contamination or hazards that may be in the food, ask trainees for examples of contaminants/hazards that may affect products at various stages in the overall food chain. Capture examples given on the flipchart, showing where the contamination may occur and add some examples to supplement where the delegates do not provide sufficient examples in other parts of the food chain e.g. pesticides in cereal production in agriculture. e.g. Agriculture – Pests, Pesticides, herbicides, chemicals from ground water, disease, bacteria from soil or guts, GM, dirt and debris, contamination of milk from teats, soil, mastitis (Staphs), people Primary processing – Contamination by guts during slaughter/cutting, soil/dust, contamination from other batches during transport (milk, cream) or processing (fruit), pieces of machinery, growth of microorganisms if stored Secondary processing – Contamination from other ingredients, work surfaces, people, cross contamination via work surfaces, utensils, growth of microorganisms if stored Retailing/catering – if food not covered contamination/cross contamination as above. If covered and prepared correctly – poor storage could lead to growth of microorganisms, damage to packaging prevent adequate control of growth. Consumer – If not covered and stored correctly any of above Next slide outlines why it is important that we appreciate the various contaminants possible so we can be informed about how this might affect our ingredients and what we might do to deal with these contaminants e.g. a cheesemaker might buy in raw milk; they may then pasteurise/heat treat it before making cheese because they may not know what might be present in terms of food poisoning bacteria. If they produce the milk themselves and have full knowledge of it’s microbiological quality, they may decide to make a raw milk cheese because they are confident the raw milk is free from pathogens

Approach to Food Safety Management
All links in the food chain are responsible for food safety within the scope of their own ‘link’ in the operation Trust and confidence in suppliers is vital Traceability is needed in case any problems arise Design food safety systems to prevent problems rather than rely on end-product testing All food & drink companies need a good food safety system Trainer to use this summary slide to highlight that all the links in the food chain are responsible for making sure the food they handle and produce is safe. We use good practices to make sure everything that needs to be in place is in place and working correctly. We make sure we have the right process controls and manage these at all times

A Food Safety System The attitude to food safety in a food business is very important for the production of safe food so we’re now going to talk about what needs to be in place for food safety. Trainer note: This slide is part of a sequence of slides to create animation

Discussion What do you think needs to be in place so a food business can demonstrate food safety is a priority and is effectively managed? Ask the Delegates the question. Write their answers on a blank flip chart but group them without using titles according to whether their answer relates to Management commitment Good Practices/Pre-Requisites HACCP related/process control activities From the answers given, put a heading to each group and then use the analogy of a building – explain that, in this case, it will be a Greek Temple. Ask the group what they would want to start with if they were building a Greek Temple that needed to stand for thousands of years They should say ‘good foundations’ . Trainer to ask which of the three groups on the flipchart would constitute ‘good foundations’ – they should say ‘Management Commitment’. The trainer can use the next slide to bring up the ‘foundations’ on the slide.

A Food Safety Culture Food Safety Culture & Management Commitment
The trainer can then ask what should be built next for our temple (the delegates should say ‘walls’) and the trainer can bring up the next slide showing a series of pillars Food Safety Culture & Management Commitment

A Food Safety Culture Food Safety Culture and Management Commitment
Trainer to ask delegates what they think from the remaining two groups on the flipchart represent the walls/pillars. Food Safety Culture and Management Commitment

A Food Safety Culture Hygiene & Housekeeping Planned Maintenance
Calibration Planned Maintenance Pest Control Hygiene & Housekeeping Personal Hygiene Training Supplier Controls So the pillars represent Good Practices or ‘Pre-requisites’ – these are the basic requirements that any food business should have in place – these are the things that need to be in place before HACCP is used – making sure the fundamentals are in place and working – we’ll come back to these later. So we have foundations and walls so the final element is the roof – bring up the next slide Food Safety Culture and Management Commitment

A Food Safety Culture HACCP The Process Hygiene & Housekeeping
Calibration Planned Maintenance Pest Control Hygiene & Housekeeping Personal Hygiene Training Supplier Controls Finally the trainer can explain that this represents the production process which is where we need to ‘do’ HACCP/apply the principles of HACCP to ensure that the processes are examined to identify the hazards that may result if things go wrong and, where we find parts of the process that need very tight day to day control for producing a safe product, we will focus attention to ensure those hazards are well controlled - Critical Control Points. These will need to be monitored whenever we produce to be sure that the process is in control or, if there is a problem, we know exactly what needs to be done to restore control, capture any product that may be unsafe and deal with these products so we protect the consumer. This is the essence of the HACCP system Using the building analogy, the trainer should challenge the delegates with questions So what would happen to our building if the roof leaked or blew off? What would happen if the walls cracked or one of the pillars crumbled? What would happen if the foundations were not strong enough? All the answers should be similar – the building will/may fall down and it’s integrity has been damaged – in food terms, this means potentially unsafe food. The trainer can then indicate that all the components are needed and each of these component parts needs further examination…. bring up each heading in turn explaining that we need all these components to give us a robust way of managing food safety during day to day working Food Safety Culture and Management Commitment

‘The Foundations’: Having a Food Safety Culture
What does a good Food Safety Culture involve for the people involved in the Company? Trainer – explain to delegates that each of these elements are important so each needs to be explored a little more Ask the delegates what they think ‘having a food safety culture’ involves? Trainer to take answers and put on the flipchart Next slide will show summary of the key points Take the answers and paraphrase – bring up bullet points and reinforce

‘The Foundations’: Having a Food Safety Culture
Clear commitment to Food Safety from Management Knowledge and skills to manage Food Safety Ensure levels of supervision are in place and right for the business Members of Staff given responsibility and authority

‘The Walls’ Making sure that Good Practices (or Pre-requisite Programmes) are in place Hygiene & Housekeeping Planned Maintenance of Buildings & Equipment Pest Control Waste Control Supplier Controls Personal Hygiene Training Control of Allergens Trainer to explain that this is not an exhaustive list, there may be others e.g. wood and glass controls

ACTIVITY Planning requirements for SALSA: Pre-Requisite Programmes
Trainer to divide the group into pairs and allocate a topic to each pair . Refer to the SALSA standard that the delegates should have brought with them and provide the relevant SALSA ‘Tools and Tips’ sheet for the topic and a piece of flipchart paper and marker pens. Ask the pairs to prepare a poster detailing the requirements for the allocated topic. Ask them to refer to the SALSA standard and the Tools & Tips and prepare a brief feedback session on the topic to give to the rest of the group to explain the requirements to the rest of the group. Trainer to constantly encourage and reinforce and to get delegates to think about importance of management/supervision in ensuring standards are set appropriately and well managed on a day to day basis. Handout 3

Good Practices or Pre-requisites
Manage hazards not specific to a particular process or product Support and underpin HACCP Allow HACCP to focus on what are the most significant hazards for a particular product or process Trainer: use this slide to summarise how pre-requisites and HACCP fit together and highlight the importance of pre-requisites being managed well so they can be relied upon. HACCP can then be used to identify and manage the food safety concerns associated with the particular process or product Trainer to highlight that physical and chemical (including allergens) hazards are often controlled by pre-requisites

‘The Roof’: ‘Doing’ HACCP
Preparation: Group Products & Processes to decide on the different HACCP Plans required for each Makes applying HACCP efficient & effective Saves time and complexity Trainer to make it clear that HACCP principles are intended to be applied to the process because the pre-requisites or good practices are used to make sure the food production environment is suitable for the production of safe food. Before HACCP is applied, the company needs to work out how to make sure all food processes have HACCP principles applied to them. This is usually done by grouping products that are processed in the same way and doing HACCP for each group. Any additional processes can be done as additional HACCP plans. We will look at examples to illustrate this.

ACTIVITY Example: Cheesemaker How many HACCP plans are needed?
ACTIVITY: Trainer explains that a cheesemaker makes a hard cheese, 3 similar but different shaped mould ripened soft cheeses and 3 flavour variant hard cheeses, based on the hard cheese but chopped with various additional ingredients (apricots, cranberries and dates), re-pressed into moulds, demoulded and then wax coated. Trainer to write the details on the flipchart for reference. Trainer to work with the group to show that the site needs 3 separate HACCP plans: Hard cheese production from milk receipt to dispatch of finished packed cheese Soft cheese production from milk receipt to dispatch of finished packed cheese Flavoured cheese production from storage of offcuts/mis-shapes from the main packing line to dispatch of finished waxed cheese including chopping, flavour additions and re-moulding

Developing a HACCP Plan
Information Sheet Developing a HACCP Plan Handouts 4 & 5 HACCP is based on some principles that were defined about 25 years ago by an international group of experts. If you are interested, these are published in a document by Codex which is in some references you will be given at the end. There are 7 principles of HACCP and to make these easier to apply, these are translated into 12 steps – this is only mentioned because other people may refer to these. HANDOUT 4 (12 Steps in Preparing a HACCP Plan) shows these but don’t worry about them now as we’ll refer to these principles as we go through the course. HANDOUT 5 contains a Glossary for quick reference as we go through the course

Writing a HACCP Plan Starting to write a HACCP Plan:
Write an ‘introduction’ for each HACCP Plan What it covers Who was involved in writing the HACCP The references used e.g. SALSA standard 2. Know (or find out) the chemical, physical and microbiological make-up of the product(s) You’ll need to gather information about your product Next slide is handouts for gathering information and a blank sheet for writing an introduction When we write a HACCP Plan, it needs to be written for other people to read (e.g your EHO) so that they know what you mean. Avoid shorthand. You will refer back to your plan in the future so it’s important that you write an introduction to your HACCP Plan. There’s a proforma you can use that you will be given in a few moments. You will need to gather some information about your product before you start.

Gathering information and writing an Introduction
ACTIVITY Gathering information and writing an Introduction Handout 6: Gathering Information about Your Product The background should include looking for information on whether any food poisoning or other incident has been associated with the product or similar products – so that gives an idea of what the hazards might be •Review the specification for the product including –Ingredients listing and nutrition (may include origin) –Chemical properties e.g. Acidity, Salt, Moisture –Physical properties e.g. texture, appearance, aroma –Microbiological properties e.g Maximum level of specific pathogens, Total bacterial count, spores –Allergens present •Check legislation •Look for food poisoning or other hazards associated with the product or similar •Look on FSA website and register for news in the product area, codes of practice •Critically assess ingredient list to see from where hazards could come •Google or other internet search but do not be tempted to copy someone else’s HACCP •Trade Associations etc •Environment within the product and ingredients for microorganisms to multiply (temperature, acidity, moisture) •Whether an additive or preservative is important in preservation •Intended shelf-life •Intended packaging and labelling •Will the food be cooked or is it ready-to-eat? •What is possible abuse potential? Example Background Search Cheese – possible sources of information •Food Safety and Dairy Regulations including temperature control and microbiological limits •Recommendations for microbiology of Ready-to-eat foods (Health Protection Agency) – possible pathogens from cattle in milk e.g. E.coli (0157), Salmonella, Staphylococci (mastitis) •Soft cheese and Listeria (from the environment) – especially in pregnant, elderly and young •Specialist Cheesemakers Association/Chilled Foods Association e.g. Google “Cheese” – Food Safety Article from FDA Retail Food Safety Program Information Manual on Date Marking of Cheese FOOD CODE SECTION: Ready-to-Eat, Potentially Hazardous Food, Date Marking. ISSUE: Are all cheeses required to be date marked when the processor's package is opened and the product, in whole or in part, is repackaged or wrapped for sale or service or for later use in a food establishment? DISCUSSION: The Food Code specifies that ready-to-eat, potentially hazardous food prepared and held refrigerated for more than 24 hours in a food establishment must be marked at the time of preparation to indicate the date by which the food shall be consumed or discarded. It further stipulates that refrigerated, ready-to-eat, potentially hazardous food prepared and packaged by a food processing plant shall be clearly marked, at the time the original container or package is opened in a food establishment, to indicate the date by which the food shall be consumed or discarded. Additionally consider whether references and links to relevant sources of information (see handout) may be useful Refer to HPA Microbiological properties of ready-to-eat food – gives source foods for pathogens and significance of micro counts – good for pre-requisite adequacy check too. When they get back from the course, they can use this as a checklist to gather information about their products ACTIVITY 7: Preparing for HACCP. Trainer to give out the ‘Introduction’ template and ask delegates to fill one out for their product (fairly briefly as they will not have been able to do the initial ‘gathering information’ phase) Handouts 6 & 7

Writing a HACCP Plan Starting to write a HACCP Plan:
Write an ‘introduction’ for each HACCP Plan What it covers Who was involved in writing the HACCP The references used e.g. SALSA standard 2. Know (or find out) the chemical, physical and microbiological make-up of the product(s) 3. Prepare a Process Flow Diagram for each HACCP Plan and confirm it is correct (i.e. ‘walk the line’) Next step is flow process diagram – (move on to the next slide )

The Process Flow Diagram
What is it? Ask what the delegates understand by the term ‘Process Flow Diagram’ - A diagram showing the process used to make the product in the form of a flow Have they done one before? Trainer to ask delegates to get out the ‘beefburger’ exercise they should have prepared and brought with them. Explain that we will jointly ‘convert’ this into a Process Flow Diagram as an example. Trainer to ensure they stress the need to do this accurately without omitting any processes. Trainer to ask delegates whether they have experienced any problems with doing Process Flow Diagrams historically

You cannot have an effective and applicable HACCP plan without a Process Flow Diagram The Process Flow Diagram must show all processing steps including exceptions! The best person to record the process steps to make your product is the one who knows most about it - YOU! Next slide for activity heading

Creating a Process Flow Diagram
ACTIVITY Creating a Process Flow Diagram ACTIVITY: Creating a Process Flow Diagram Trainer to ask delegates to take the process list they prepared for the course and convert it into a process flow diagram. Provide and suggest they use Post-It notes to lay the process out on a table before writing it on paper – makes it easier to make changes! Once the Process Flow Diagram is completed, someone should ‘walk the line’ to make sure the Process Flow is correct and sign it off – this is important because this gives the framework for identifying hazards and putting the controls in the right place. This is something you can do when you return to work. If you’ve forgotten something, it’s not a problem because it’s never too late because the process is still there – and you can go over it as many times as you like when you go back.

Example: Process Flow –Chicken Pie
Step 1 Intake raw chicken, onions and ready made pastry Step 2 Store in raw materials chiller Step 3 Dice chicken & onion Step 4 Fry chicken and onion, add stock and simmer Step 5 Roll out pastry and line pie tin/cut pie lid Step 6 Fill pastry case with chicken mix and add pastry lid Step 7 Glaze pie with egg wash Step 8 Bake in oven at 180°C until golden brown Step 9 Remove from oven and cool Step 10 Place in cooked food chiller Step 11 Film wrap and label Step 12 Pack into boxes and despatch We have chosen chicken pies as many processes are similar and people can relate to it. So it’s a good example to see how the process works. Trainer: explain the process flow for Chicken Pies and run through providing further description to ‘paint a picture’ for the delegates, confirming that they understand the process

Example of a simple flow process
Information Sheet Example of a simple flow process Trainer to provide HANDOUT 8 : (Process Flow Diagram) Handout 8

Common problems: You were given a Process Flow Diagram and HACCP plan from another similar (or not!) company A consultant came to you and presented you with a ready-made Process Flow Diagram and HACCP plan A consultant came in and wrote your HACCP plan from what you told him/her and you didn’t ‘walk through’ the detail Trainer to explain the problems associated with complex process flow diagrams and how, practically, they can be improved – trainer to refer to the example given in handout 8

We go through our process, a step at a time, to identify hazards
Hazard Analysis We go through our process, a step at a time, to identify hazards What is a Hazard? We then identify the Control Measures we have in place to control these hazards Ask delegates what they understand by the term ‘hazard’. The legislation refers to hazard analysis. This simply means that a structured approach is used to identify hazards and where they might occur which then allows us to see where they need to be controlled. For example, there will be pathogens in meat, which might be a hazard but if we are then cooking it, then that is the point in the process where that hazard will be controlled. Once we have completed the hazard identification, we decide if the hazard needs to be controlled i.e that it can really happen and can really cause illness and then we need to make sure effective controls are in place To recap, there are a number of categories of hazards. Trainer to ask delegates for some examples for each

Information Sheets What is a Hazard? Handouts 9, 10 & 11
Give out Handout 9 (Micro), Handout 10 (Physical) & Handout 11 (Chemical Hazards) run through the microbiological handout, explaining that we need to know which harmful microorganisms (called pathogens) are associated with the products we are handling because we will then know which controls are going to be suitable. Trainer take the delegates through Handout 9, providing examples. Then move onto the next pages Handouts 9, 10 & 11

Microbiological Hazard Control
Microbiological growth or survival is usually controlled using temperature or a process step Cooking Rapid Chilling Chilled Storage Acidity Contamination is usually prevented using pre-requisites & ‘rules’ Cleaning Personal Hygiene Next slide for chemical and physical hazards

Chemical & Physical Hazard Control in the Workplace
Control is often achieved through Pre-requisites – although there are exceptions Control of physical hazards is often achieved through rules in the workplace or by removal of contaminants e.g. sieves Control of chemicals is usually based on rules for handling & cleaning Run through HANDOUTS 10 & 11 on Chemical hazards and Physical hazards Control of Physical Hazards Generally prevention of physical hazards are by physical means e.g. not having drawing pins in processing area, controlling engineers working, not using materials that splinter/contaminate – wood, foil. Also specifying quality and control of foreign bodies in ingredients. There may be equipment used within the process for the removal of physical hazards e.g. sieves (for stones) but these would generally be covered when HACCP is carried out. Control of Chemical Hazards Specifying quality and control of chemicals such as pesticides and herbicides etc in ingredients Control of chemicals used during processing (refer to chemical control tips) Locked cupboard storage, labelled in-use, control of dilution, checks on concentration and rinsing, recipe control for preservatives etc.

Finding Hazards in your Process
Use your common sense History of your product Known incidents Review complaints received as an indication Trainer to discuss ways in which hazards can be identified by delegates for their process/s Those developing HACCP Plans do need to decide whether a hazard is likely to need to be controlled by a specific control measure or is adequately controlled by a good practice/pre-requisite be a genuine one and sort those that are genuine ones from those that are not. It is tempting to err on the side of caution and rate all the hazards you can think of as being genuine. The type of information on the slide suggests things that should be taken into consideration. Trainer – there is an example below but you can use one of your own. Ask the delegates to make decisions about risk. Providing the message is put across and delegates are comfortable with the concept of risk assessment, the objective is achieved. If we take a non-food example, and consider going out for a walk as an activity. Ask the delegates for examples of hazards they might associate with this activity (e.g. tripping over a rock, getting hit by a car mounting the pavement, getting hit by a car because you cross the road from between parked cars, getting hit by a meteor falling from the sky. These are all harmful but some are more ‘genuine’ concerns than others. Tripping over a rock could happen and you might be slightly injured but it’s not important enough to warrant special attention. Getting hit by a car mounting the pavement is potentially harmful but because it’s unlikely to happen, you may not take any special precautions. Similarly, getting hit by a meteor falling from the sky is likely to be fatal but as it is highly improbable, you are not going to take special precautions. Getting hit by a car when crossing the road is quite likely if you do not take precautions so some measures to prevent the problem are necessary e.g. using a crossing and ensuring you wait until the traffic stops before crossing.

Starting your Hazard Analysis
ACTIVITY Starting your Hazard Analysis ACTIVITY: Hazard Analysis ( Handout 12 Blank Hazard Analysis & Risk Assessment Form)) Delegates to take the process steps from their previously developed personal Process Flow Diagram and transfer them onto the blank forms provided. Trainers to check delegates are happy with this step Handout 12

Hazard Analysis When we do hazard analysis, we need to document out thoughts and decisions. We generally use a form similar to that shown above (Handout 12)

Brainstorming the Hazards for Chicken Pies
Example: Brainstorming the Hazards for Chicken Pies Have chicken pies or a similar product caused an incident of harm or potential harm to the consumer, or caused a recall? What went wrong? Where would you look for information about your product – past history incidents, legislation? We are now going to apply the concepts we’ve discussed to manufacturing chicken pies. For this example, the focus will be on a hazard that you may recall from the news, Salmonella We will assume for this example that the HACCP team working on this is competent in applying HACCP, there is someone with knowledge of microbiology specifically, and a production person who has detailed knowledge of the equipment and the process. The team would do the following - Research Salmonella on the internet Look at incidence of Salmonella in raw chicken and the measures that control it and find that: Salmonella is destroyed by thorough cooking If the cooked chicken is cross contaminated after cooking with Salmonella from the raw chicken, the Salmonella could be present in the cooked chicken and cause food poisoning in the consumer Salmonella causes food poisoning and can be fatal The team could then do some work to see what level of Incidence of Salmonella is present in raw chicken and can be done to control it e.g. cooking to achieve a core temperature of >75°C

Hazard Analysis We start to populate the blank Hazard Analysis proforma Here are the process steps from the Process Flow Diagram for our example If we now think about the hazards at each process step Trainer to ask delegates the following: Should we only look at the one hazard? No – there may be others, e.g. bone, other pathogens e.g. Campylobacter For the first step (purchasing) what would the main hazard be ? And the fifth step (roll out the pastry and line line/cut lid), what would the main hazard be?

Hazard Analysis Trainer to explain the choice of hazards and highlight the detail with which the hazard is written – what the hazard is (we’ve focused on Salmonella) and ‘Presence’ if it comes in with the raw material or ‘Contamination’ if it comes from something in the processing environment or ‘Survival’ if it fails to be removed or destroyed by processing (might be a sieve used to remove foreign material that fails to remove foreign bodies if there is a hole in it, for example) or ‘Growth’ (really only applies to microbiological concerns) where temperature is relied upon to prevent growth of micro organisms but there is a problem with temperature abuse. If there are no hazards identified, it is good practice to write this in the form

Looking at your Hazard Analysis
ACTIVITY Looking at your Hazard Analysis Activity using handout 12 continued…. Delegates to now look at the blank Hazard Analysis & Risk Assessment Form that they have completed for their process steps and think about identifying hazards. Ask each delegate in turn to look at any step in their process and ask what might the main hazard or hazards be? Ask for possible suggestions from the other delegates and agree a couple of suitable hazards and causes for the selected process step and suggest the delegate records these details in the ‘Hazards’ column. If there are two trainers i.e. more than 6 delegates, each trainer to work with half the group to keep the momentum up Trainer to then work with delegates to fill out the Hazard Analysis & Risk Assessment table for their products

Control measures are at the heart of the HACCP Plan
Activities that control the hazard to prevent, eliminate or reduce it to a safe level e.g. cooking, sieving Control measures are at the heart of the HACCP Plan The next step is to look at control measures. Trainer to explain that it’s any activity that prevents a hazard occurring OR eliminates/destroys the hazard OR reduces it to an acceptable level. Control measures are at the heart of the HACCP Plan as it is these that control the hazard and it is these that we need to monitor at places in the process where the control measure is vital for producing a safe product

Hazard Analysis Trainer to ask delegates for step 1 for raw chicken and 5 for rolling pastry , what are suitable control measures?

Hazard Analysis So, the control measure at step 1 is to specify that you want to minimise the Salmonella in the raw chicken, you need to use an approved/reputable supplier. If you want to minimise the possibility that the food handler could contaminate the pastry with Salmonella, you need to use personnel trained in reporting illness and have procedures for dealing with the situation to minimise the possibility that this could happen. Both these issues are managed on a day to day basis by the pre-requisites but despite this, the Salmonella issue on the raw chicken remains. We then do a ‘risk assessment’ to determine which hazards are ‘significant’ for food safety.

Identifying your Control Measures
ACTIVITY Identifying your Control Measures Using Handout 12 continued: Trainer to ask delegates to work on their hazard analysis for their product and identify suitable control measures for each identified hazard (If there are two trainers, each trainer to work with half the group). Ask for an example from each delegate to ensure all delegates understand what a control measure is.

Deciding which Hazards are Significant
Which hazards are realistically likely to happen? (Risk/Likelihood) Have occurred historically within the company Have occurred within the industry Can be considered a possibility Which hazards are genuinely harmful? (Level of Harm/Severity) Could cause an outbreak of food poisoning Could cause illness/injury We can use various methods for assessing the likelihood and severity to determine significance.

Information Sheet Risk & Severity Handout 13
Trainer to provide HANDOUT 13: Likelihood vs Severity On to next slide to view the handout and discuss Handout 13

Deciding on Significance
Trainer: discuss HANDOUT 13: Likelihood vs Severity and explain how it works. Also explain that there are many similar methods and delegates can select an alternative – the chosen approach does not need to involve scoring, could just decide on the basis of yes or no but it is useful to score as it adds weight to the decision taken. Probably the difficulty is when a hazard scores ‘4’ – coloured yellow here. This is neither low nor high for significance so a decision has to be made and it can be helpful to consider whether it will need active management on a day to day basis to protect the consumer – if ‘yes’, then it’ll be significant and if ‘no’, it’ll be low significance and can be treated like the others with the same level of significance. Ensure delegates understand Risk = likelihood of occurrence and Severity = the impact on health Next slide shows chicken pie again so this can be discussed

Hazard Analysis This is the slide we just completed, with the control measures completed for the hazards identified. Considering the first step, Purchase, we identified a hazard and control so we want to consider whether it is significant. On the basis of 1-3, how might we assess the likelihood of this occurring? Perhaps ‘high’ scoring a 3 as raw chicken is known for this form of contamination. For severity – the outcome could be food poisoning and possibly fatality so also a ‘high’ and therefore a 3. We then multiply these score together to calculate a significance of 9. We can compare this with the previous slide to determine that this is significant. For the 5th step, rolling the pastry, we might perhaps assess that although the severity is the same ( i.e. high or 3), the likelihood is low or 1 because we have pre-requisites in place for personal hygiene and reporting illness so an overall score of 3 – which we deem to be low and therefore not significant The next slide shows the details filled in….

Hazard Analysis Looking at step 1 for chicken first, it was decided that the likelihood of chicken containing Salmonella coming in was a likely event and given a score of 3 (high) suggesting that it could happen about once a week. It was also decided that if someone ate the chicken with the Salmonella in, then the severity of that would be high 3 - which gives a total of 9. Therefore this was determined as a CCP. At step 5, it was decided that although personnel with a Salmonella infection could be in the factory, it was unlikely as there are good pre-requisites in place. Handout 13 to be provided.

Calculating Significance for your Products
ACTIVITY Calculating Significance for your Products Ask delegates to use the approach to decide on significance for their own HACCP. Trainers to work with the group to make sure they have understood the concept.

Critical Control Points: Why identify them?
At a Critical Control Point, the Control Measures/Controls MUST work to ensure the food produced at this stage of the process is safe You only need to consider ‘significant’ hazards and then decide where in the process they should be controlled. The reason we need to identify Critical Control Points is so that we know where we need to make absolutely sure that the control measure/s are working, which we do by setting standards to work to, by carrying out regular checks to see if the control measure is working (monitoring) and defining what actions should be taken if the monitoring checks indicate that the control measure isn’t working correctly. Explain that it is really all about focusing attention on the parts of the process where it is possible that hazards will occur. There is no right number of Critical Control Points but generally it would be expected that there were no more than 5 or 6 in most processes. If there are more CCPs identified than there need to be, resource for managing them will be spread too thinly and the genuine CCPs may not receive enough attention and food safety could be compromised.

Common Critical Control Points (CCPs)
Heating and/or hot-holding Rapid cooling (to avoid ‘danger zone’) Chilled storage Acidity development Control of available water – drying, addition of salt or sugar Additives i.e. levels of preservatives You do need to identify CCPs specifically for your business in response to the outcome of your hazard analysis but there are some commonly identified CCPs. As shown on the slide. Trainer to describe the circumstances under which each of these might be CCPs

(based on a simplified version from Highfield Publications)
Decision Tree (based on a simplified version from Highfield Publications) In terms of identifying Critical Control Points, you can use your judgement. You need to ensure there is a CCP identified for each significant hazard but where these significant hazards occur at the beginning of the process, there is a possibility of a later/subsequent processing activity ‘dealing’ with the issue. This might be the case where raw chicken does contain a significant hazard e.g. Salmonella but this will be destroyed if we cook the chicken fully at a later process step e.g. baking so the CCP will be at the baking step. Sometimes people struggle with identifying CCPs so we can use a decision tree as in the example shown. There is a more complex version used by larger companies, based on a decision tree from Codex Alimentarius but this version works well. You don’t need to use this to determine your CCPs but if you are interested this is a simple example. It can help you to reduce the numbers of CCPs in your process.. Handout 14

Critical Control Point Identification

Identifying your Critical Control Points
ACTIVITY Identifying your Critical Control Points Delegates then asked then to use the approach for their own HACCP

Making Critical Control Points work
How do we do this?... Set standards for safety for the Control Measure in question (called Critical Limits) Check the Control Measure is working within the set safety standards (called Monitoring) Plan what to do if the Control Measure, when checked, isn’t working (Called Corrective Action) Once the Critical Control Points have been identified, the business knows where focus is required to ensure the process, at that point, is under control. This is done at each CCP by …… (Trainer to run through the points on the slide.) We will look at each of these in turn…..

Critical Limit The safety value for the Control Measure
i.e. the standard which, if not met, means the food produced may be unsafe and the process is ‘out of control’ The Critical Limit is the standard that must be met at the CCP for the process to be regarded as being under control The Critical Limit must relate to the control measure at the CCP and be something that is easily measured because this limit, when monitored, will tell the person doing the monitoring whether the control measure is working and that the food being processed is safe in this respect. If the Critical Limit is found to have been exceeded when monitoring is undertaken, then action needs to be taken immediately to rectify the situation and prevent any potentially unsafe food from reaching the consumer

Critical Limits – ‘The Rules’
Each Critical Limit must: Relate to the Control Measure Be easily measurable during production e.g. temperature, and give a result quickly Be specific e.g. less than 5ºC or >72ºC for 15 seconds Critical limits are the standards used for Monitoring; exceeding Critical Limits always results in Corrective Action So, to recap, Critical Limits…… Trainer to run through the points on the slide Trainer to ask delegates - There are some legal critical limits for temperatures – what are these?

Target Limit The safety ‘buffer zone’ for the Control Measure
Limits which are more strict than critical limits Used to reduce the risk of a non conformity by assuring that the critical limits are met. Explain to the delegates that target limits can be used along with critical limits. They are more strict than the critical limit so are early warnings that the process is going out of control.

Being Confident - Producing Safe Food
Validation You need to ensure Critical Control Points are at the right points in the process You need to be sure that your Critical Limits are correct so you can produce safe food Where can you find out what critical limits you need to include? Check: Legal limits - where? ‘Good practice’ limits from reputable sources Conduct some trials to provide proof This is always difficult! This is what is called ‘Validation’ – is the contents of the plan ‘valid’ i.e. capable of producing safe food. It only needs to be done once for each HACCP Plan but does need reviewing or repeating if anything changes How would you know whether your CCPs are in the right place? (Take suggestions from delegates) Summarise their suggestions and conclude that whilst there may be other parts of the process where there are controls for the hazards, it will be the final point in the process/best opportunity to control the hazard (like the finest sieve of a series of sieves). The ‘crunch’ question is …. If I don’t get control right at this process step, the consumer could suffer the consequences In terms of Critical Limits, these are frequently either well known (e.g. achieving 70°C for 2 minutes in the centre of a product or 75°C in the centre of a product) and available from lots of sources or from EHOs or they are determined by the limitations on equipment e.g. using the finest sieve possible for the nature/particle size of the product . We need to be careful to make sure all parts of the control are included in the Critical Limit e.g. temperature and time for cooking, if this is relevant Sometimes companies want to do something different e.g. long, slow cooking which is below the conventionally recognised temperatures for cooking but for much longer times e.g. slow cooking of lamb shanks – in this case, the company would need to do some trials with some ‘before’ and ‘after’ microbiological tests to prove that their minimum temperatures and times were suitable for destroying pathogens

Monitoring Checks or tests undertaken during processing to make sure the controls in place at Critical Control Points are within the Critical Limits Be specific What tests or checks are required? How often they should be carried out? Who is to do the tests and checks? Where we have identified CCPs, we need to check that the control measures are working within the Critical Limits – we need to Monitor. Carry out CCP monitoring routinely, every time the process is operational, as this that will tell us whether the control measures are working. The things that need to be defined for Monitoring are detailed on this slide and all aspects of the control measure need to be monitored so if time and temperature are important, then both need monitoring. We describe exactly how monitoring should be done – is it by placing a sanitised thermometer probe in the centre of each baked pie immediately after cooking or is it by placing a sanitised probe in pies in all four corners of a tray of pies for trays in the top, middle and bottom of an oven rack? We need to decide how often to monitor the CCP – the only ‘rule’ is that it should be done within the working day (so that products that are affected will not have left the factory and can be found and dealt with) but the frequency may be ‘every 15 minutes’ or ‘hourly’ or ‘each batch’. This needs to be given careful thought Ask delegates – what factors would you take into account when deciding on frequency? Take delegate answers and summarise – Depends how frequently a loss of control might be encountered (the more often, the more frequently you may wish to monitor so that there is a manageable amount of product to deal with) Depends how quickly products are despatched from site (if products are despatched within an hour of production, monitoring should be frequent enough to identify a problem before the products leave site We also need to identify who is responsible for monitoring and detail this in the HACCP Plan – usually be job title Ask delegates what they would do if they find, when they monitor, that the Critical Limit has not been met Once answer received, go to next slide…

Corrective Action Must include:
What to do with the possibly unsafe food How to restore control at the Critical Control Point Examples include: Stopping production of any more product Finding the products manufactured since the last ‘good’ check so they don’t leave the premises Fixing the problem that caused loss of control Calling the supervisor/manager Corrective action is very important. When things have gone wrong, people tend to ‘flap’ and do what comes into their heads, which may not be the right course of action. In HACCP, we define exactly what needs to be done when the monitoring shows us that there is a problem with not achieving the Critical Limit at the CCP. The main requirements are detailed on the slide and examples are as shown. It is important that the person operating the equipment can take the right initial action to ensure there is no further production of unsafe products and that potentially unsafe products are being found and segregated. Calling the supervisor is secondary as the operator should have the authority to take initial corrective action to minimise the impact of the problem and then decisions on what to do with the potentially defective product can be made later.

Identifying your Critical Limits, Monitoring and Corrective Action
ACTIVITY Identifying your Critical Limits, Monitoring and Corrective Action ACTIVITY Provide HANDOUT 15: PROFORMA: Blank Critical Control Point Sheet Ask the delegates to take a couple of examples of CCPs they have identified for their process and identify suitable Critical Limits, Monitoring and Corrective Actions. They should also explain how they might prove that their Critical Limits at their CCPs are going to be effective i.e. valid. Trainers to work closely with delegates to ensure any problems or lack of understanding is identified and addressed. Ask each delegate to describe one of their CCPs and how they have decided to ‘manage’ it i.e. Critical Limit, Monitoring and Corrective Action Handout 15

We now have a plan for producing Safe Food … a HACCP Plan
A few easy to follow ‘rules’ for making the HACCP Plan work: The HACCP Plan needs to be written down The HACCP Plan needs to be implemented Records need to be kept to show Critical Control Points are being actively monitored Records need to be kept to show Corrective Action(s) are taken when a Critical Control Point is not working properly Trainer to highlight that, at this stage, the business now has a HACCP Plan and has done some work to prove that it will work (validation) Trainer to ask delegates Why does the plan need to be written down? Why does the HACCP Plan need to be implemented? Why do we need to keep records?

Implementing HACCP Once the HACCP plan is ready, it must be introduced to the business to be effective by... Implementation is key to the success of the system. Sadly there are businesses with HACCP Plans that were prepared and have since sat on a shelf without being implemented fully and are only brought out for enforcement personnel and customers/auditors to look at. Once the HACCP Plan is ready and has been shown to be valid, it needs to be implemented which is not complex but mostly about managing change. Trainer to ask delegates – what do you think is involved in introducing the HACCP Plan requirements to a food production process and how do you think this can be achieved?

Implementing HACCP Once the HACCP plan is ready, it must be introduced to the business to be effective by... Communication to the workforce Awareness, Training, Briefing Implementation is about transferring the requirements of the HACCP Plan into reality! This may include making sure that the workforce are aware of the reasons that HACCP has been used and to obtain their backing.

Implementing HACCP Once the HACCP plan is ready, it must be introduced to the business to be effective by... Communication to the workforce Awareness, Training, Briefing Confirming the pre-requisites are working Introduction of CCPs and associated records Introduction of extra checks (verification) It will involve introducing the monitoring activities at CCPs and designing suitable record forms (maybe asking the people who have to fill then in to design them!) Monitoring equipment may need to be bought and/or provided e.g. calibrated thermometers One of the main pieces of evidence that a HACCP Plan has been implemented is the generation of records of monitoring for each Critical Control Point

Implementing HACCP Once the HACCP plan is ready, it must be introduced to the business to be effective by... Communication to the workforce Awareness, Training, Briefing Confirming the pre-requisites are working Introduction of CCPs and associated records Introduction of extra checks (verification) Regular reviews to make sure changes are captured and introduced correctly (evaluated for food safety) Importantly, however, there also need to be a way of capturing any changes that are to be made …. Trainer to ask delegates what type of changes might be made that might affect food safety? e.g. new equipment, change to the recipe or the process, changes to ingredients, changes to workflows etc Any changes would need to be evaluated as part of a review of the HACCP Plan to make sure that their impact is taken into account

Why keep Records? To demonstrate product safety is being managed
For audits Customer Environmental Health SALSA Insurance May be used for employee training Provide history for problem-solving Identify potential problems (adverse trends) So, why keep records? Tom Clancy says in the film ‘Debt of Honor’ “If it isn’t written down, it didn’t happen” Trainer to ask delegates to think about the sorts of people who may visit their business. Who has visited in the past year or two? Did they ask to see any records? Were they specific in their requirements or more general?

Types of Documents & Records
The HACCP Plan Procedures and Work Instructions Records to show Pre-Requisites are working Records to show Food Safety is being managed Monitoring & Corrective Action Verification Review HACCP Plan: Once implemented, this may sit on a shelf for most of the time but don’t forget it can have other uses. What might these be? (e.g. as a training aid) Procedures & Work Instructions: What type of procedures/work instructions might be needed? (Refer to SALSA standard and discuss when and why written procedures may be necessary) Ask for examples and write on flipchart (Cleaning Schedules, Procedures for Handling Glass Breakages, Product Recall Instructions, Procedures for Monitoring CCPs) Records of Pre-requisites and their Operation: Ask for examples and write on flipchart (Goods Intake Inspection Records, Ingredient & Packaging Specifications, Pest Control Inspection Reports, Records of Calibration, COSHH sheets, Training Records Records to Show Food Safety is Being Managed : Ask for Examples and write on flipchart (Records of CCP monitoring and corrective actions, records of validation, microbiological testing records (verification), records of internal audits, Records of checks carried out to see if the monitoring records have been filled in correctly, records of changes made to the HACCP Plan, records of reviews of the HACCP Plan)

Example: A Standard Operating Procedure
Information Sheet Documents & Records Example: A Standard Operating Procedure HANDOUT 13: Examples of Standard Operating Procedure for Storage Temperature Control and associated records Handout 16

Designing Records for CCPs
What should be included on a Critical Control Point record? Trainer to ask delegates what they would include on a Critical Control Point record and write on a flipchart Refer back to Handout 16 Standard operating procedure and example record.

Records should be formatted to make completion easy
Designing Records for Critical Control Points Records may include: Details of: The Critical Limit Brief details of the Monitoring procedure & Frequency of check Corrective Action requirements & space for details of Action Taken Traceability information (e.g. product names/batch codes) Space for Comments Space for the reviewer to sign/initial and date Records should be formatted to make completion easy Trainer to summarise – here’s some ideas we prepared earlier….. At a minimum, you should make a note of what was made on each day and batch coding information, to allow for traceability. It can be useful to detail some of the requirements for the CCP – reminders about Critical Limits, what the Monitoring method is and what Corrective Actions are required Ask - Why is it a good idea to complete your records while you’re in production? Why do you need to put the time and date of production? Can you think of an example when making a record of time/date might be useful in the future? (example answer – when dealing with a customer complaint) Why should the record be initialled by the employee? If computers are to be used to store record information, what sort of controls might need to be considered?

Designing a monitoring record for a CCP
ACTIVITY Designing a monitoring record for a CCP Handout 17 ACTIVITY – Designing a Monitoring Record for a CCP - PROFORMA Trainer to work with delegates and pose challenges: Do you need to add any extra information? How much can you practically fit on 1 page A4? (the more that can go on one record sheet, the better!) Would this work in your business? Could people use your form easily? Handout 17

Remember: These records may be your only proof!
Record-keeping tips Never pre-record data or use ‘ditto’ Never postpone making entries or rely on your memory Modifications: Never use ‘Tipp-Ex’ or erase Do: cross out and correct; and initial any changes Standardise forms Remember: These records may be your only proof! Trainer to highlight some useful tips for record keeping It may seem obvious but don’t write anything down in advance of taking your temperatures etc – don’t assume anything (because ASSUME makes and ASS out of U and ME). Similarly, don’t write ditto or delay making records. Ask - Why might this cause you problems? It is considered bad practice to use Tipp-Ex or own brand correcting fluid or to erase anything permanently, why is this considered poor practice? Use standardised forms because a familiar theme will help people navigate the paperwork. Think about websites like Amazon and ebay, which ones work and which don’t?

Information Sheet Tudor & Sons Handout 18
Finally, think about why you keep these records. Trainer to discuss the legal concept of due diligence. Refer to the Tudor & Sons story with regard to falsifying records HANDOUT 18 – Tudor & Sons Newspaper Article. Handout 18

Confirming/Verifying Products are Safe
How do you know your HACCP plan is working? Double-check your records Perform internal audits Investigate complaints Product testing Verification is the phrase used to describe the process you go through to double check that your HACCP plan is working. How could you do this? Well, suggested ways are looking at old records – have CCP limits been exceeded? Why could this be? For example, does your food not always cool as quickly as you would like? Could that be due to the nature of the equipment that you’re using or the way the food is laid out? Internal audits help you take snap shots of the HACCP system to see if all is well. Complaints may have underlying trends which show that all is not well with the HACCP system, like product going mouldy before its best before date or complaints about meat smelling “off” before its use by date. Finally, there’s product testing. Usually micro testing. Ask your lab to advise what tests are needed and what the acceptable limits are.

Reviewing Records Review records prior to despatching product.
Review to ensure: Completeness Have the critical limits been met? Proper Corrective Action taken? Trainer to ask - Why might you need to review CCP records before product is sent to customers? What might you need to think about if a CCP hasn’t been met? Think about storage temperatures, cooling time / temperatures and ingredients. What sort of corrective action might need to be taken?

Retention of Records Keep the records:
for at least one year beyond maximum possible shelf-life (do consider any ‘home-freezing’ of products etc) in good condition filed to make access or eventual disposal easy Once your records have been made, I’m afraid you’ll have to keep hold of them for a while! Why is this? This can be a headache for a lot of businesses – big and small, so give archiving and the nature of your records some thought. How compact could you make your records without them becoming a burden?

Thinking about Changes
Discussion Thinking about Changes Ask the delegates: What sort of changes might prompt you to review your HACCP Plan or Pre-requisites? Write the answers on the flipchart Some suitable answers are detailed on the next slide….

Changes New process flow New ingredient or change to an ingredient
New product Review annually If you change your process flow or make a new product or add a new ingredient, you will probably need to change your HACCP plan. A common example is a butchery that starts to make its own stuffing to put in the birds at Christmas, how might this affect the HACCP plan? (Talk about ingredients, allergens, microbiological risks, process flow, machinery, temperatures). In any event, you should have a look at the HACCP plan every year to make sure that it is still relevant.

Do Check Act Plan Check and improve!
Remember, Plan, Do, Check Act – all about continually making the system better and better. Plan – You’ve made sure you have the right pre-requisites and you have drawn up your HACCP Plan and associated procedures and records. Do – You’ve put the HACCP Plan in place, remembering to train your colleagues accordingly Check – Review what you’ve done, has it worked? Is it complete? If the forms you’ve drawn up don’t work – change them! After all, you’re going to have to live with them every day! Act – Make the necessary improvements.

What does the law require? - The Principles of HACCP
Principle 1: Conduct a Hazard Analysis Principle 2: Identify Critical Control Points Principle 3: Establish Critical Limits Principle 4: Establish Monitoring Procedures Principle 5: Establish Corrective Actions Principle 6: Establish Verification Procedures Principle 7: Establish Documentation & Records So we’ve nearly reached the end of the course. We have been through how we use HACCP and the various considerations along the way. This slide summarises the principles of HACCP and ties in with the handout we gave you at the beginning of the day. You can see that we have now covered all the principles of HACCP and trust that we have dispelled some of the myth and left you feeling more confident about using the technique for your business.

Applying HACCP & Making Safe Food
Finally, a reminder of the logic behind HACCP Trainer to explain that: The key is to identify the Hazards – the contamination that can be present in ingredients or packaging or that that can occur during processing or, if microbiological, can grow or fail to be killed Once the real hazards have been found (i.e. those that can happen and can cause illness or injury), we need to identify the measure or measures we can use to control these hazards – to prevent them or remove them or reduce them to a safe level - the Control Measures Once we know where in our process we are going to control them i.e. at the Critical Control Points, then we can set some Critical or Safety Limits in relation to the control measure. We can then Monitor the control measure against the Critical Limit. If we find there’s a problem with the control measure working, we can take some Corrective Action. Controlling food safety all comes back to the control measures – these are the key to food safety. If we make sure the control measures are working to the standards we know will work (because we can prove it) and we have put the right control measures in place to control the hazard, we can be sure we will make safe food! Good Luck and thank you for your participation….

Information Sheet Useful references Handouts 19
HANDOUT: List of useful references Handouts 19

In summary... Don’t be afraid of the jargon HACCP is simply a tool
HACCP is very logical A HACCP plan helps YOU to make safe food A few final thoughts… There is a lot of information available on the internet and some of it can confuse so be cautious when looking for information. Just because it is on the internet and comes up when you Google, doesn’t mean that the information is good. If you are comfortable with the logic behind HACCP you will be fine and if you can justify your decisions about what goes in your HACCP Plan, then you are well placed to be confident. Never rest on your laurels though, if something food safety related happens within the industry or within the business, always review your HACCP Plan to see if you have considered the risk and, if necessary, have it covered in your HACCP Plan. Seek advice if you need to. You’ve had blank templates and some example handouts you can use for writing your HACCP Plan – or you may decide to design your own.

Hazard Analysis Critical Control Point Training

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