ISO 22000 : ISO 22000 Support Programs - II

ISO 22000 Support Programs

We discussed certain parts of the support programs on the last article, most of these areas are we discussed time to time, but when you consider ISO 22000 implementation in a factory, it is very critical that you need to thoroughly consider implementing support programs prior to the implementation of ISO 22000 food safety management system. Otherwise it will be very difficult to implement support programs at the last minute; it is advised to start with GMP requirements and to implement prerequisite programs in your factory well before you start thinking of an ISO 22000 FSMS. If you have completed such requirements, it will be much easy for you to develop the HACCP on top of the existing GMP and PRP’s with relevant support programs. Then it is much easier to apply rest of the requirements step by step to certify your organization for ISO 22000 FSMS.

The biggest mistake small scale industrialist do today is; they never think about the organizing and standardizing basic requirements at the beginning and try to maximize the production and sales without thinking the environment they use to manufacture foods. Sometime later when they realize that they need some kind of a food certification to survive in today’s industry; they start thinking of these requirements in a very short time line. Thus it is most difficult sometimes if the promises and other supportive mechanisms are not stream lined and planned according to the stipulated food manufacturing requirements, where these support programs have a very important role.       

Approved Supplier Program

Appropriate controls should be in place to ensure that the safety of supplies is acceptable. Businesses need to set up a system for approving and reviewing their suppliers. Your business may choose some of the following approaches:

Some businesses may decide to purchase high risk foods only from suppliers who have a food safety system in place.

Businesses should have a list of all suppliers used, their contact details and materials they supply. This would assist with traceability.

Ideally the performance of suppliers should also be monitored which may include a history of their ability to supply within an agreed specification.

Ideally you should keep a record of all suppliers and a copy of their HACCP certification to prove accreditation status.

Suppliers test results, where applicable, are to be available for audit. Supplier certification may be an appropriate alternative. All information should be recorded along with any correction action taken.

Reference:  Supplier Evaluation and Selection

Good Food Handling Practices

It is essential to ensure good handling practices are maintained throughout the whole process, where all foods are to be stored and transported under the conditions prescribed in the applicable Food Standards in the country or specific standards practiced by the industry (GMP, HACCP, ISO 22000, etc.) They must meet temperature and hygiene requirements.

A business should establish policies and procedures for good handling practices in the following areas:

Packaging

Storage

Handling practices

Temperature monitoring procedures

Waste management

Food disposal

Some of the types of issues and checks may include:

A Pre-Operational Checklist –This type of check can be used at the commencement of each shift/day to ensure the premises and equipment is satisfactory to use. Also refer to the Hygiene and Sanitation Program.

Receival of Raw Materials - all raw materials are checked to ensure product quality and all relevant information along with any corrective action taken is recorded. Also refer to the Approved Supplier Program.

Storage - there are three important factors to consider when storing food:

Appropriate temperature control

Stock rotation

Prevention of contamination

If storing and transporting refrigerated food, ensure temperature is at 5°C or less. As an example, prior to dispatch of the product, the temperature is recorded on the product dispatch sheet.

Good Food Handling Policies

Here is a typical list of some of the issues for consideration when you develop policies relating to good food handling practices.

Storage

As soon as supplies are received from relevant suppliers, they should be placed in the appropriate storage area (freezer, cool room or dry storage area) for the quarantine before issuing to the production.

The supplies must be tested and verified against stipulated standards followed by the relevant food manufacturer and if the relevant standards are not met, then return the supplies back to the relevant supplies with the test results.   

Packaging materials must be stored in a manner that prevents contamination by dust, vermin and chemicals. Opened boxes of packaging material must be sealed between production days.

All stock should be rotated to ensure the oldest stock is used first. Prior to use, any expiry dates are checked and if the product has expired it is not to be used.

Products should be either stored in the original packaging or transferred to food-grade packaging. If product is not packaged/ sealed, then it should be covered.

Raw food is stored separately from ready-to-eat food, and if separate storage areas are not available, ready-to-eat food is stored above raw.

All dry products are stored in a manner to prevent contamination from moisture, dust, dirt, pests and rodents.

All perishable/refrigerated/frozen foods must be stored under temperature control.

Refrigerated products – stored at 5°C or less

Frozen products – stored at -18°C or less

All products are stored and transported at 5°C or less.

Waste management

Procedures for handling waste materials and cleaning waste bins should be documented.

Food disposal

Unsafe product is to be disposed of properly to ensure that it is not included with food for sale.

Food may need to be disposed of because:

Of a product recall;

The product has exceeded its shelf life; or

The product does not comply with your food safety program.

If food is to be disposed of but cannot be discarded immediately it is marked clearly with ‘HOLD’ for disposal, and separated from other food.

Equipment

Unsealed wood and timber are not to be used in food handling areas.

All equipment should only be used for what it was intended and should be kept clean and well maintained.

Equipment such as cool rooms, freezers and ice rooms should be serviced and temperature gauges should be calibrated regularly (eg. every six months).

If food transport vehicles are used they must be maintained in a clean and sound condition so that food does not become contaminated.

If refrigerated food is transported, vehicles with refrigeration units may be used and should be serviced regularly to ensure the vehicle will maintain food at 5°C or less. Records of maintenance activities should be kept.

Cleaning and Sanitation Program

Proper cleaning and sanitation will decrease the likelihood of the food becoming contaminated and will discourage pests from the premises and vehicles. In related to food operations, cleaning can be explained as “the removal of waste, dirt and grease from equipment, premises and vehicles”. “Sanitation reduces the number of microorganisms present”.

A cleaning and sanitation program should be set up to include a cleaning schedule and cleaning procedures which are documented. The schedule procedures should cover processing areas, amenities, cool rooms, storerooms, wash rooms etc. as well as utensils and equipment, floors, walls, drains etc. The following should be addressed in the procedure:

How is the cleaning/sanitation conducted,

Frequency of cleaning,

Use of chemicals,

Other points to consider regarding your cleaning and sanitation program are;

Cleaning detergent solution strengths, times and temperature requirements are to be in accordance with the manufacturer’s specifications.

All chemicals used for cleaning and sanitation should be stored away from any food.

Generally, food handling areas should be cleaned at least daily and food contact surfaces, equipment and utensils should be sanitized more frequently if required.

The verification of the effectiveness of cleaning should be determined; this may include visual assessment and regular environmental swabbing as part of the verification program.

A pre-operational hygiene check of the premises may be carried out to ensure that all surfaces are clean prior to use and recorded on a Pre-operational Checklist.

Evidence that all chemicals used in the processing area and hand wash stations are suitable for use with food products should be available. Chemicals must be well labeled at all times.

Material Safety Data Sheets (MSDS) for all chemicals stored and/or used should be kept. It is suggested that a list to be kept of all chemicals used on site, their suitability for use in food processing areas (if the chemical is to be used in a food handling or processing area) and where the chemical is used.