Kitchen hygiene practices and HACCAP

1. © SALSA 2012
HACCP
Hazard Analysis Critical Control Point
Training
Level 1: Awareness
January 2017

2. Today’s session will include:
Food Safety
 What it is and why it is important
 How a company can achieve a system that produces safe food
 The structure of a food safety system including HACCP
 What is involved in implementing HACCP
 The roles for personnel within a food business in producing
safe food

3. Learning Outcomes for this course
1. Know the purpose of a HACCP system
2. Know the features of a HACCP system
3. Know how hazards are controlled
4. Know how to manage a Critical Control Point

4. © SALSA 2012
Discussion
Why is Food Safety Important?
Tell us what you think!

5. 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?

6. 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!

7. What are the Laws?

8. What are the 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

9. 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
You CAN do HACCP!

10. © SALSA 2012
Discussion
What do you think are the Consequences of
NOT Managing Food Safety?

11. Consequences of a Hazard reaching
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 closed
and consequences for the workforce

12. © SALSA 2012
Discussion
What Makes Food Safe?

13. What Makes Food Safe?
 Freedom from contamination
– Microbiological (Pathogens)
– Physical
– Chemical (including Allergens
 Making sure pathogens cannot grow

14. What Makes Food Safe?
Safe food is obtained by
 Correct and careful processing
 Protecting the food from further contamination

15. © SALSA 2012
Discussion
How can we prevent contamination with
microorganisms?

16. Preventing Contamination
Use of reputable suppliers
Effective cleaning
Compliance with personal hygiene requirements
Correct food storage

17. Preventing Growth of Microorganisms
How?
– By making sure microorganisms
(bacteria, moulds, viruses or yeasts)
cannot get what they need
So what do microorganisms need?

18. Preventing Growth of Microorganisms
How?
– By making sure microorganisms
(bacteria, moulds, viruses or yeasts)
cannot get what they need
So what do microorganisms need?
Warmth

19. © SALSA 2012
ACTIVITY
Handout 1

20. Back to the Beginning…..
As soon as we harvest food, it starts to deteriorate…..

21. Common Preservation Techniques
• Heating
• Drying
• Use of Chemicals
• Chilling/Freezing
• Acidity
• Manipulation of gases
around the product

22. The Food Chain
Agriculture
Secondary
Processing
Primary
Processing
Retailing/
Catering Consumer
So what do we do?..........

23. © SALSA 2012
Discussion
Potential contaminants/ hazards in the
food chain

24. The Approach to Food Safety
Management
 All ‘links’ in the food chain are responsible for food safety in their
own operations
 Confidence and trust in suppliers is vital
 Traceability is needed in case there are any problems
 Design food safety systems to prevent problems rather than rely on
end product testing
 Food companies need a good ‘food safety system’

25. A Food Safety ‘Culture’

26. © SALSA 2012
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?

27. The ‘Foundations’ -
Having a Food Safety Culture
What does a Food Safety Culture involve for the
people involved in the Company?

28. 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

29. A Food Safety ‘Culture’
Food Safety Culture & Management Commitment

30. A Food Safety ‘Culture’
Food Safety Culture and Management Commitment

31. The ‘Walls’ –
Making sure that Good Practices
(or Pre-Requisite Programmes)
are in Place

32. The ‘Walls’
Making sure that Good Practices
(or Pre-Requisite Programmes) are in Place
 Hygiene & Housekeeping
 Planned Maintenance of Buildings and
Equipment
 Pest Control
 Waste Control
 Supplier Controls
 Personal Hygiene
 Training
 Control of allergens

33. 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

34. A Food Safety ‘Culture’
Hygiene
&
Housekeeping
Planned
Maintenance
Pest
Control
Personal
Hygiene
Training
Supplier
Controls
Calibration
Food Safety Culture and Management Commitment

35. A Food Safety ‘Culture’
Hygiene
&
Housekeeping
Planned
Maintenance
Pest
Control
Personal
Hygiene
Training
Supplier
Controls
Calibration
HACCP
The Process
Food Safety Culture and Management Commitment

36. The ‘Roof’: ‘Doing’ HACCP
Preparation
– Grouping products & processes to decide on
the different HACCP Plans required
 Makes applying HACCP efficient &
effective
 Saves time and complexity

37. © SALSA 2012
HACCP
Awareness

38. What is HACCP?
(Hazard Analysis and Critical Control Points)
It’s a technique for making sure that
 All the relevant food safety concerns are identified
 A practical and sensible plan is designed to prevent
or control these food safety hazards during
production by focusing attention on ‘Critical Control
Points’ (CCPs)
…………………Simple!

39. How does HACCP work?
 The ‘Good Practices’ or ‘Pre-requisites’ are introduced and
confirmed as being in place and working
 The business writes HACCP Plans to cover all the products made
HACCP Plans are implemented by ensuring ‘Critical Control Points’
(CCP) are closely monitored during production
 If a problem is found at a ‘CCP’, defined actions are taken to
resolve the problem. This makes sure the affected products don’t
reach the consumer

40. © SALSA 2012
ACTIVITY
What is a HAZARD?
Handout 2

41. Hazard Analysis
Undertaken by a group of people within the company who
 Draw a diagram of the steps/stages in the process being examined
 Take each step in the process and consider any hazards that may
occur and the cause
 Decide which of the identified hazards are genuinely likely to occur
 Decide what measures can/should be taken to prevent or control
each of these hazards – these are ‘CONTROL MEASURES’

42. What are Critical Control Points (CCPs)?
 Points in the process where it is Critical to
Control the hazards identified by hazard analysis
Each CCP must be under control during
processing/manufacturing to make sure safe
food is produced - otherwise the consumer
may be harmed

43. How do we make sure Critical Control
Points (CCPs) are under control?
 Use agreed and valid limits (called CRITICAL LIMITS)
e.g. cooking to a minimum core temperature of 82°C
 MONITOR the control measure at an agreed frequency
e.g. take core temperatures of the product to ensure the Critical Limit has
been met, every batch
 Follow CORRECTIVE ACTIONS defined in the HACCP
Plan to protect the consumer

44. 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 products produced since the last ‘good’ check
 Fixing the problem that caused loss of control
 Calling the supervisor/manager

45. Reassurance!
 HACCP does not mean more work – just different, targeted work
that is more effective for food safety
 Most businesses only have a few Critical Control Points
 Controlling and monitoring a Critical Control Point is usually done
by the person responsible for operating that part of the process
 HACCP needs to be clear ‘who does what’ and what needs to
happen in the event of a problem

46. What does HACCP look like in
practice?
A few sensible ‘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 Actions
are taken when the Critical Control Point is not
working properly

47. 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

48. 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)

49. © SALSA 2012
Discussion
Designing Records for CCPs
What should be included on a Critical Control
Point record?

50. Designing Records for CCPs
Records may include:
 Details of:
 The Critical Limit
 Brief details of the Monitoring procedure & frequency of check
 Corrective Action requirements
Traceability information (e.g. product names/batch codes)
Space for Comments eg details of corrective action taken
Space for reviewer to sign/ initial and date
Records should be formatted to make completion easy

51. © SALSA 2012
ACTIVITY
Let’s look at a CCP record
Handout 3

52. The Role of the CCP Monitor
 Controlling the food production process
 Monitoring Critical Control Points (doing tests and checks) at
the right frequency to see if the process is under control
 Taking Corrective Actions as defined in HACCP Plan
 Keeping records to show the CCP is well managed
 Flagging issues/suspicions about the process
 Suggesting better ways of working at the CCP

53. Record Keeping Tips
 Never pre-record data or use ‘ditto’
 Never postpone making entries and rely on your memory
 Modifications:
– never “Tipp-Ex” or erase
– line out and correct; initial any changes
 Standardise forms
Remember: These records may be your only proof!

54. © SALSA 2012
Information Sheet
Tudor and Sons
Handout 4

55. Confirming or Verifying that Products
are Safe
How do you know your HACCP plan is working?
 Double check your records
 Perform internal audits
 Look at complaints
 Product testing

56. Reviewing Records
Review records prior to despatching product to ensure:
 Have the records been correctly completed?
 Have the critical limits been met?
 Has proper corrective action been taken if a critical
limit was not met?

57. Retention of records
 Keep for at least 1 year beyond maximum possible
shelf life (consider home freezing etc)
 Keep the records in good condition
 Keep the records filed to make access or disposal easy
 Consider different ways of retaining records

58. © SALSA 2012
Discussion
Thinking about changes

59. Changes
 New process flow
 New ingredient or change to an ingredient
 New product
 Annual review

60. Making it Better and Better!
Do
Check
Act
Plan

61. 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