A JOURNEY OF HACCP CERTIFICATION (The Case of ... 2-3 May 2011 A JOURNEY OF HACCP CERTIFICATION (The...

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ICQI-Lahore, 2-3 May 2011 ICQI-Lahore, 2-3 May 2011 A JOURNEY OF HACCP CERTIFICATION (The Case of Expresspac) By Ijaz Yusuf Director CSCR, UMT, Lahore Email: [email protected] & Amjad Naeem MR, Expresspac Email [email protected] ABSTRACT: ExpressPac is a manufacturer of packaging materials for direct or and indirect use to food & beverages companies like Unilever, Nestle, Coca Cola, etc so there was a high demand to build a system that could ensure the issues related to food safety supply chain. ExpressPac decided to go for first for ISO 9001:2008 certifications and then for HACCP to overcome the issues associated with food safety and builds the customer confidence. No doubt there were many challenges like basic infrastructure, financial strength, system’s expertise, limited staff, trainings lack of support from the front line managers to achieve this target but there was commitment of the top management to make this painful journey to a success story. What are the challenges faced by the company and deployment strategy to go certifications first for ISO 9001:2008 and second for HACCP. After gap analysis against HACCP codex, the developed strategy was split in three stages: in

Transcript of A JOURNEY OF HACCP CERTIFICATION (The Case of ... 2-3 May 2011 A JOURNEY OF HACCP CERTIFICATION (The...

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

A JOURNEY OF HACCP CERTIFICATION

(The Case of Expresspac)

By

Ijaz Yusuf

Director CSCR, UMT, Lahore

Email: [email protected]

&

Amjad Naeem

MR, Expresspac

Email [email protected]

ABSTRACT:

ExpressPac is a manufacturer of packaging materials for direct or and indirect use

to food & beverages companies like Unilever, Nestle, Coca Cola, etc so there was

a high demand to build a system that could ensure the issues related to food safety

supply chain. ExpressPac decided to go for first for ISO 9001:2008 certifications

and then for HACCP to overcome the issues associated with food safety and builds

the customer confidence. No doubt there were many challenges like basic

infrastructure, financial strength, system’s expertise, limited staff, trainings lack of

support from the front line managers to achieve this target but there was

commitment of the top management to make this painful journey to a success

story. What are the challenges faced by the company and deployment strategy to

go certifications first for ISO 9001:2008 and second for HACCP. After gap

analysis against HACCP codex, the developed strategy was split in three stages: in

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the 1st stage, the common areas of the ISO & HACCP were addressed. In the 2nd

stage, different -requisite programs were established to go before the 3rd stage i.e.

HACCP plan. The stage of HACCP plan is the last control to look down on the

food safety issues that has been filtered by the pre-requisite programs. This paper

attempts to highlight the implementing strategy step by step overcoming the

challenges faced by the company and can be value added input for corporate

world.

Key Words: Quality, Food Safety, HACCP, Certification

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INTRODUCTION:

1. HACCP:

It means Hazard Analysis of Critical Control Point. It is the standard to tackle the

food safety issues comprising by the following steps/ stages:

Used Procedure and Formats are given in the Annexure

STAGE #: 1

PRE-REQUISITE PROGRAMS

STAGE #: 2

HACCP TEAM

STAGE #: 3 & 4

PRODUCT DESCRIPTION & ITS INTEDED USE

STAGE #: 5

PRODUCTION FLOW DIAGRAM

STAGE #: 6

ON SITE VERIFICATION OF FLOW DIAGRAM

STAGE #: 7 & 8

HACCP— HAZARD ANALYSIS WORKSHEET/DETERMINATION OF CCP’s

STAGE #: 9-14

HACCP PLAN SUMMARY

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2. COMPANY:

Contact Information

Company Name ExpressPac Pvt. Limited

Contact Person Dr. Muhammad Hussain (CEO) & M. Amjad Naeem (MR)

Company Address 45 Km Multan Road Lahore, Pakistan

Postal Code 55261

Telephone & Fax Number +92-42-35383477

Mobile Number 0300-8422641

Website www.expresspac.pk.

Basic Information

Business Type Manufacturer

Total Area 143500 SFT

Total Covered Area 21895 SFT

Brief Company History/Milestones

Business Start up as Express Packaging:……….1999 Reorganized as Expresspac (Pvt.) Ltd.: ...2007/ April, 08 Certified for ISO 9001:2008………….….2010 Certified for HACCP…………………….2010

No. of Employees 55 – 60 People

Employee Facilities Free Residence & Mess

Products/Services • Stretch Wrap Film• Shrink Wrap Film• Wrapping Film• Lamination Film• Antistatic films & bags• Printing Film• Ghee Film• 3-Layer specialized films

Used as primary, 2ndry & tert. packaging material in foodindustry) , Hot Melt Wax, CaCO3

Our Markets Locally working MNC’s like:

Nestle Pakistan Ltd; Unilever Pakistan Ltd; Engro Foods Ltd;

Tetrapak Pakistan Ltd; Packages Ltd Lahore; Haleeb Foods

Ltd; ICI Pakistan Ltd; Coca Cola Beverages; Sufi Soap

(Hamza Vegetable Oil); Century Paper & Board Mills;

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Shezan International; Riaz Bottleres Lahore (Pepsi); Metro

Cash & Carry; Makro Cash & Carry; Dynamic Packages

(Pvt) Ltd; Al-Aziz Packages Ltd; Converters (Pvt) Ltd; M &

F Commercial; Pack Tech (Pvt) Ltd; Aamir Foods Industries;

Pioneer Pakistan Seed Ltd; Becton Dickinson; Mehboob

Industries (Shan Ghee); Gujranwala Food Industries

ORGANOGRAM:

OBJECTIVE OF EPL (EpressPac Pvt Limites):

EpressPac Pvt Limites was interested to assure and improve the processes so that

EPL could be selected as a best manufacturer of packaging materials for direct or

and indirect use to food & beverages companies like MNC’s and other top

businesses so there was a high demand to build a system that could ensure the

issues related to food safety supply chain. ExpressPac decided to go for first for

ISO 9001:2008 certifications and then for HACCP to overcome the issues

associated with food safety and builds the customer confidence.

PROBLEMATIC AREA:

1. Lacks of basic Infrastructure:

There was a huge need to invest to develop the infrastructure:

Organization Chart

Admin& HR

MaintenanceAccounts

/Finance &Purchasing

Sales &Marketing

Store &Dispatch

QA&

QCLab

Production

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Change Over Room

Lockers

Provision of Wash Basin & Hand Dryer in Production Hall

Employee Health Screening

Provision of Additional PPE’s for HACCP

Lack of Pest Killers (Glue Pad, Mouse trap & feed, Bait Stations,

Insecticides, Insecticide Spray, Antidermide Spray)

Store Racks

Machines Hoppers Cover

Food grade lubricants

Boards for Hanging SOPs

Sign Boards (Entrance, Exit, etc)

Whitewashing

Machines Paint

Blocking of washroom near Kitchen

External Calibration of Equipment

2. Financial Strength:

No doubt, the company had an interest to compete the market but being a small

unit had not enough resources to fulfill the requirements in few days. But in spite

of being small unit, the management developed the basic infrastructure within the

time.

3. Lack of System Expertise & Awareness:

Although the certification will was continued from the last many years, yet there

was serious lack of system expertise even the routine works were not recorded

properly because of high turnover rate of Management Representative (MR)

4. Purchasing Department & Marketing Department Work:

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In these departments, no record was in practice and all the activities related to these

departments were verbal.

5. HR Department & QA Department Work:

No existence of these departments. So the concept like Document & Data

Control, Trainings, System Audits, etc was very weak.

6. Store Work:

There was no record related to stock but when there is a need, the employee was

assigned to count the relevant stock. There was a very difficult to declare that any

item is present in the store although it was available & being purchased before few

days ago. In case of emergency, mostly new purchasing was carried out.

The practical approach to control waste management was very poor i.e. all types of

wastes but all were collected in a way that it becomes difficult either anyone

variety is present or not.

7. Production Department Work:

There were very limited documents Only the Job Card was prepared that contained

the information about PO & Production Status and there was neither process

monitoring, traceability nor proper production record.

8. QC Laboratory:

Only the final inspection of only the film was prepared. The QC department was

just maintaining the record of testing the final product without bothering the results

are OK or not OK. There was consideration when the production results was not

match the customer specified results.

9. Administration Department Work:

Only one register was used to record the said information.

10.Limited Staff: Purchasing Department:

Not well defined, all the three CEO and two Directors including Maintenance

Incharge were involved in purchasing.

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11.Limited Staff: Marketing Department:

The CEO himself along with one more employee that left the company in early

days of certification preparation was running this department.

12.Limited Staff: HR Department:

As there was no existence of the HR department, so there was no any employee to

execute the HR related functions.

13.Limited Staff: QA Department:

There was a vacancy but the appointed employee was responsible to do the QC

activities. The company was at a first stage of preparing Quality Manual through

Deputy General Manager.

14.Limited Staff: Store:

No regular employee was appointed in store. CEO, production department and

maintenance department were jointly running the store.

15.Limited Staff: QC Department & Production Department:

The strength of these departments was as required.

16.Lack of Support from Front Line Managers

As there was lack of staff and the employees had no awareness about the

management systems so they were terrified to do the work in this style.

17.No Hierarchy System

Every employee was considered to responsible for every business activity but no

one was answerable.

18.High Turnover:

At the management level, the turnover was controlled but at the operator level the

turnover was absolutely unsatisfactory that was causing to train the employees

frequently and ultimately it becomes difficult to achieve the implementation targets

successfully.

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19.Resistance to Change

As there is a human nature that they resist the change because it is a quite new

imitative for a packaging industry so that is why people resist the change and

create hurdles for implementation.

20.Company Culture

The company was initially a one man show the man who took lot of pain to create

this business kingdom. People are used to listen and obey the verbal orders.

Documentations, written policies and the officer memos are not the part of

company culture. It was very difficult to change the people from individual focus

to system focus.

21.Reluctance to Acquire New Skills

Most of the employees belong to rural areas and they are reluctant to learn the new

skills. They focus only to the primary function but to learn quality related

education was not their main focus.

22.Lack of Support from Front Line Managers

Line managers and executives want to make the place in the eyes of top

management so they do not encourage the Quality staff to ponder in their areas and

share the information with the top management that is why they do not extend the

support to HACCP Team involved in HACCP activities.

WORKING METHODLOGY:

Along with the resolution of the above mentioned problematic Issues, there was a

need to cover all the steps required for certification starting from documentation to

certification including to build a team that is capable to achieve certification target

successfully.

To resolve the problematic Issues and to kill down the issues of “Lacks in Basic

Infrastructure & Financial Strength”, carefully, financial targets were also

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achieved. The financial strength was not resulted more problems because there is a

need of enough time to build the structure.

To kill down the issues of “High Turnover, Lack of System Expertise &

Awareness & Lack of Support from front Line Managers”, much training were

conducted about System, Culture and Motivation. 5S system was introduced for

best Store Management related to both Raw & Finished. Further the waste store

was separated along with partition so that problems produced in formulation

creating by the improper waste management could be resolved.

To kill down the issues of “Limited Staff”, the work has been done more than 8

hours by following the principles of Hard & SMART working.

To kill down the issues of “No Hierarchy System”, proper hierarchy was approved.

To Document, Implement & Certification:

For this purpose, the following steps were carried out:

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DEPLOYMENT STRATIGIES:

First to implement ISO 9001:2008 and then HACCP

Expel out the Non-Supporting Employees

Phase-I: Gap Analysis for ISO 9001:2008

Phase-II: Departmentalization/ Hierarchy Development

Phase-III: Each Department Documentation Structure

Phase-IV: Training about System

Phase-V: Implementation

Phase-VI: Internal Audit

Phase-VII: Certification for ISO 9001:2008

Phase-VIII: Gap Analysis for HACCP

Phase-IX: Align 9001 with HACCPPhase-IX: Developed PRP’s

Phase-IX: Implemented PRP’s

Phase-X: Improve through Internal Audits

Phase-XI: Developed HACCP Plans

Phase-XII: Implementation

Phase-XIII: Internal Audit

Phase-XIV: Certification for ISO 9001:2008

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LITERATURE REVIEW:

In literature and corporate world many food safety initiatives like Global Food

Safety Initiative (GFSI), Hazard Analysis for Critical Control Points (HACCP),

Good Manufacturing Practices (GMP), Safe Quality Food (SQF), British Retail

Consortium (BRC), Food Safety Management System (ISO 22000) and American

Institute of Baking Standard (AIB Standard) exist. A representation of common

ground between food safety schemes was needed to enhance food safety, ensure

consumer protection, and to strengthen consumer confidence.

To address these needs, the Global Food Safety Initiative (GFSI) was coordinated

and launched in May 2000 by CIES--The Food Business Forum, an independent

global food business network headquartered in Paris. Founded in 1953, CIES has

developed numerous programs for retailers and supply chains, and continues to

facilitate the development of common positions and tools on strategic and practical

issues affecting the food business. CIES shares best practices throughout 150

countries.

The GFSI is a nonprofit foundation created under Belgian law with a mission to

work on continuous improvement in food safety management systems to ensure

confidence in the delivery of food to consumers.

The GFSI guidance document was developed for guidance and to set commonly

agreed criteria as a framework to which food-safety-related schemes can be

benchmarked. It is not a standard and GFSI is not involved in certification or

accreditation activities.

Currently in its fifth edition, the guidance document provides the procedure for

benchmarking of food safety management schemes, the key elements for the

production of food within a conforming food safety management standard (i.e.,

good manufacturing practices, or an HACCP program or equivalent system ), and

guidance on the certification processes of a food safety management system.

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The GFSI guidance document is freely available on the CIES web site

(www.ciesnet.com).

Currently there are four food safety standards formally benchmarked to GFSI.

They are the British Retail Consortium’s (BRC) Global Standard for Food Safety,

the International Food Standard (IFS), the (Dutch) National Board of Experts

Hazard Analysis and Critical Control Point (NBE HACCP) Option B, and the Safe

Quality Food (SQF) 2000 Code. (11)

Hazard Analysis Critical Control Point Systems (HACCP)

In the 1960's, NASA wanted to guarantee that the food for astronauts on space

flights was totally safe. The task of producing "Zero Defect" food was contracted

to the Pillsbury Corporation who developed the first system of Hazard Analysis -

Critical Control Points or HACCP (16). In 1995, HACCP was instituted in the

seafood industry and monitored by FDA. The HACCP idea is now becoming the

standard throughout the entire food industry. HACCP is based on the identification

and control of physical, chemical and biological hazards. The goal of HACCP is to

control and prevent the contamination of the food products. The reasoning for

HACCP implementation are 1stly it demonstrate and documents a commitment to

deliver safe food products to consumer, 2ndly a HACCP program also helps make

food processing more efficient and less costly in the long run and 3rdly FDA and

USDA become more involved in food safety, and in particular HACCP, more

regulations will be issued.

Physical Chemical Biological

Bone Acids E.Coli 0157:7

Metal Solvents Salmonella

Wood Sanitizer Staph. Aureus

Rubber Pesticides Lister Monocytogenes

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Glass Lubricants Shigella

Rodent Caustics Cryptosporidium

Plastic Sulfites Campylobacter

Stone Allergens Yersinia Enterocolitica

Hair Aflotoxin Bacillius Cereus

Paper Hapatitis A

(28)

HACCP is Hazard Analysis and Critical Control Points Principles that focus

attention on food safety at every step of the journey from the farm to the

consumer's table (19). Prerequisite programs such as current Good Manufacturing

Practices (GMPs) are an essential foundation for the development and

implementation of successful HACCP plans (20). HACCP significantly reduces

the risk of food contamination in two ways: First, it anticipates potential problems

or failures and does not depend only on a final inspection. Second, because it

identifies problems during the process rather than at the end of the process or once

the product moves into the supply or marketing chain there is a greater likelihood

of resolving the problem at hand as opposed to pursuing a product recall (16). Its

importance is first in the U.S. HACCP has become a legal requirement for the

fish, poultry and meat industries (16), and 2ndThe proactive HACCP Food Safety

Management System is based on the CODEX Alimentarius Commission

adaptation of the FAO/WHO Guide or guidelines for application of the Hazard

Analysis Critical Control Point system, which is by far the most internationally

recognized safety and quality assurance system for all food related industries

directly in the food chain (26).

Good Manufacturing Practices (GMP)

Good Manufacturing Practices (GMP) direct all persons working in direct contact

with food, surfaces that food might contact, and food packaging materials, to

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conform to sanitation and hygiene practices to the extent necessary to protect

against contamination of food from direct or indirect sources (16).

Safe Quality Food (SQF):

The SQF Program (Safe, Quality Food) is one of the world's leading food safety

and quality management systems, designed to meet the needs of retailers and

suppliers worldwide. The Program provides independent certification that a

supplier's food safety and quality management system complies with international

and domestic food safety regulations. This enables suppliers to assure their

customers that food has been produced, processed, prepared and handled according

to the highest possible standards, at all levels of the supply chain.

SQF is designed as a food safety program, but it also covers product quality,

assuring consistent quality and meeting buyer specifications. The SQF Program is

administered by the SQF Institute (SQFI),

McDONALDS-AUDIT-V-1-0-AUG1210SQF-ETHICAL-SOURCING-V-1-0

SQF2000-DOC-LEVEL-2-VER-2-0

SQF2000-DOC-LEVEL-3-VER-2-0

SQF2000-FAC-LEVEL-1-VER-2-0

SQF2000-FAC-LEVEL-2-VER-2-0

SQF2000-LEVEL-3-FAC-VER-2-0

Rpt300AuditChecklistSQF 1000 document level 2 v1 (22)

SQF 1000/2000

The SQF Program is an internationally recognized comprehensive food safety and

quality management system to cover the entire food chain from “farm to fork.”

The Program is made up of two codes (standards), the SQF 1000 Code for the

primary production sector and the SQF 2000 Code for the food manufacturing and

service sectors. Suppliers can implement a management system which meets any

of the following three levels of certification:

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Level 1: Food Safety Fundamentals: Indicates that pre-requisite programs and

fundamental food safety controls have been implemented to provide a sound

foundation for the further development of the supplier’s management system.

Level 2: Certified HACCP Food Safety Plans: Incorporates all Level 1 system

requirements, and indicates that a food safety risk assessment of the product and its

associated processes has been completed. This assessment must identify the

hazards and the actions taken to eliminate, prevent or reduce their occurrences.

Level 3: Comprehensive Food Safety and Quality Management System:

Incorporates all Level 1 and Level 2 system requirements, and indicates that a food

quality risk assessment of the product and its associated process has been

completed. Additionally, at Level 3 an organization must show that the actions

taken to prevent the incidence of poor quality have been implemented and that the

remaining quality management system procedures addressed in the standard have

been implemented. (9)

The SQF 2000 Code is designed for use in all sectors of the food industry as a

HACCP-based quality management system to reduce the incidence of unsafe food

reaching the marketplace. It is a food safety program that also covers product

quality. It offers benefits to suppliers and buyers at all links in the food supply

chain by addressing the buyer’s food safety and quality requirements, and provides

a solution for the suppliers.

First launched in 1994, The Food Marketing Institute acquired the rights to the

SQF program in 2003 and established the SQF Institute (SQFI) division to manage

the program. Now in its sixth edition, SQF 2000 Code is recognized by GFSI as

meeting its benchmark requirements. It is the only GFSI-recognized certification

system that links primary production certification to food manufacturing,

distribution, and agent/broker management certification.

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The program provides independent certification that a supplier’s food safety and

quality management system complies with international and domestic food safety

regulations. This enables suppliers to help assure their customers that food has

been produced, processed, prepared, and handled according to the highest possible

standards, at all levels of the supply chain.

Levels of certification

The SQF 2000 Code is divided into three certification levels: Level 1 covers food

safety fundamentals; at Level 2, certified HACCP food safety plans are recognized

by GFSI; and at Level 3, comprehensive food safety and quality management

system actions exceed the GFSI benchmark requirements.

The SQF program has many unique features that help ensure trust and consistency

in the auditing process. Certification bodies that are licensed by the SQFI to

perform SQF audits are subject to regular assessments of their certification and

audit activities by internationally recognized accreditation bodies licensed by

SQFI. Auditors are only permitted to perform audits in the food industry sectors

for which they have been registered, and in which they have extensive expertise

and experience. (11)

The BRC (British Retail Consortium)

The BRC (British Retail Consortium) Global Standard for Food Safety was created

to ensure supplier compliance and secure retailers’ ability to guarantee the quality

and safety of the food products they sell. Today it is used worldwide as a

framework for any business (retailers and processors) to assist the production of

safe food and the selection of reliable suppliers.

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It helps companies to select and qualify their suppliers. In other words it is going to

be accepted by the majority of food retailers as equivalent to the other

benchmarked food safety standards, such as IFS, SQF and the Dutch HACCP (22).

The BRC Global Standard for Food Safety is an accredited, certifiable standard,

and the first one to be approved by GFSI in 2000. The principles of the BRC

Global Standard for Food Safety are based on two key components: senior

management commitment and HACCP. (11)

BRC Global Standard – Packaging

Issue 2 of the BRC Global Standard - Food Packaging and Other Packaging

Materials

Content of the Standard

The standard consists of eight sections plus an associated protocol. Each section

sets out a statement of intent and all packaging suppliers will need to comply with

this statement in order to gain certification.

1. Scope

General overview of the standard, who the standard applies to and what the

requirements of the standard are.

2. Organization

Covers the requirements for the organization in terms of management

responsibility, organizational structure and management review.

3. Hazard and risk management system

Covers the requirements for a formal hazard analysis of the production process

considering foreign object, chemical and microbiological contamination as well as

packaging defects that compromise consumer safety.

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4. Technical management system

Covers the quality and hygiene policy, hygiene system documentation and control,

specifications, management of incidents and product recall, traceability system,

internal audits, complaints, supplier monitoring, subcontracting and product

analysis.

5. Factory standards

Covers the requirements for the building infrastructure, facilities and fabric,

product flow, maintenance of equipment, housekeeping, cleaning and waste

management.

6. Contamination control

Covers the requirements for foreign object training, glass control, blade control,

chemical and biological control, pest control and transport, storage and

distribution.

7. Personnel

Covers the access and movement of personnel, staff facilities, toilets and hand

washing, eating, drinking and smoking, illness and injury, jewellery and personal

items, protective clothing and hygiene training.

8. Risk category determination

In this section the supplier uses the decision tree to determine whether they are a

category A or B risk supplier. (8)

ISO 22000

The food safety management system standard ISO 22000 enables any company

directly or indirectly involved in the food chain to identify the relevant risks and

manage them efficiently.

Implementation of a food safety management system compliant with the ISO

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22000 standard changes your company’s approach from retroactive quality testing

to a preventive way of thinking (22).

The ISO 22000 food safety management standard incorporates the following

elements:

• Interactive Communication

• System Management

• Prerequisite Programs

• HACCP Principles (12)

The ISO 22000 standard delivers a common global framework of safety

requirements for all organizations in the food supply chain, including crop

production, processing, distribution, and related operations. It is an international

standard that harmonizes various existing national and industry certification

schemes.

ISO 22000 incorporates all seven of the contemporary HACCP principles and

implementation plans. Overall, ISO 22000 creates an effective framework for food

safety management, communication along the food supply chain, and control of

food safety hazards. (11)

Food Safety Management Systems: ISO 22000 or FSSC 22000?

The ISO 22000 scheme and the FSSC 22000 scheme differ slightly. ISO 22000

Certification applies to all organizations in the food chain (i.e. all including from

the farm to the food packaging producer. FS22000 Certification applies only to

food manufacturers, and is recognized by the Global Food Safety Initiative, GFSI.

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The FSSC 22000 scheme requirements are made up of the ISO 22000:2005

standard and one more document, the PAS 220:2008 published by BSI and

specifying detailed PRP requirements for manufactures in the food industry.

There has been an abundance of food safety standards in the world, but there is

also variation between standards, their implementation and auditing. With the

success that the International Organization of Standardization (ISO) has with

harmonization of standards, it was logical that they take on this issue with the

development of an ISO Food Safety Standard. The standard, ISO 22000 was

released in 2005. Since its release it has been successfully implemented in

hundreds of companies around the world. The ISO 22000 Standard can be applied

to any organization in the food chain, from the farm to the food packaging

producer.

However, the Global Food Safety Initiative is another organization playing an

important role in Food Safety Systems. This organization has "benchmarked" four

existing food safety schemes. Once a system is "benchmarked" it means that

certification to the scheme is accepted by organizations requiring a GFSI scheme.

The current list of GFSI schemes includes IFS, SQF, BRC and Dutch HACCP

(14).

After searching the web (including opinions on this site), it led me to believe that

there is little difference between many of the standards. As a matter of fact, it

seems most of them are starting to look more the same after each revision.

Similarities:

All identify PRPs as critical (with some varying degree of application)

All use HACCP as a base

All require some level of document/record control

All require a commitment to food safety

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The main difference thus far is that SQF, AIB, BRC, IFS et al. are prescriptive

standards whereas ISO 22000 is a management system standard and encourages

the user to join up the dots.

The Global Food Safety Initiative (GFSI) goal is to benchmark all major food

safety standards so that any and all are accepted throughout the world. A worthy

cause but not an easy task. GFSI has so far approved:

- BRC Technical Standard

- Dutch HACCP Option B

- International Food Standard

- SQF 2000

This "new" Dutch HACCP aims a better position than ISO 22000 at the moment.

It's a good solution for organizations who wants to meet the GFSI standards with

one assessment. (2)

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PRE-CERTIFICATION AUDIT:

Two audits were conducted and while auditing it was, cared that there is a next

audit of certification. Few major and minor non-conformances are highlighted

which was closed before the final audit.

CERTIFICATION AUDIT:

If there is will/ commitment of employees and top management & minimum

proficiency to do the specific job, then results are certainly happened.

By the Grace of Allah there was no major non conformance and we got the

HACCP Certification.

REFERENCES:

1. http://haccpcertifications.com/tag/gma-safe

2. http://www.ifsqn.com/forum/index.php/topic/12988-what-the-difference-in-food-safety-

standards/

3. http://www.saferpak.com/iso22000_art1.htm

4. http://www.foodsafetynews.com/2010/03/global-food-safety-standards---overview-and-

comparison-of-haccp-based-standards-course-2/

5. http://training.us.saiglobal.com/course/promotion.aspx?id=a0c2000000074FAAI

6. http://www.fda.gov/food/guidancecomplianceregulatoryinformation/currentgoodmanufac

turingpracticescgmps/ucm110877.htm

7. http://www.ifsqn.com/forum/index.php/topic/15401-sqf-documentation-requirements/

8. http://www.saferpak.com/brc.htm

9. http://www.bsiamerica.com/en-us/Assessment-and-Certification-services/Management-

systems/Standards-and-schemes/SQF/

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

10. http://www.cbi.eu/marketinfo/cbi/docs/food_safety_management_systems

11. http://www.qualitydigest.com/magazine/2009/apr/article/gfsi-food-safety-

standards.html#

12. http://foodsafetymagazine.com/article.asp?id=3101&sub=sub2

13. http://9001manual.com/faq.php

14. Newsletter by ISO 22000 Tools (http://www.22000.tools.com/

15. http://en.wikipedia.org/wiki/Hazard_Analysis_and_Critical_Control_Points

16. http://web.worldbank.org/WBSITE/EXTERNAL/TOPICS/EXTARD/0,,contentMDK:20

440953~pagePK:210058~piPK:210062~theSitePK:336682,00.html

17. http://www.tpsgc-pwgsc.gc.ca/ongc-cgsb/publications/nouvelles-news/calibre/013-

001/art06-eng.html

18. http://www.thebiscuitdoctor.com/manufacturing-management/safety/637-

f55353hazardanalysiscriticalcontrolpoints

19. http://ecom.coastal.com/HAC001-DVD-

ESP(CoastalU)/SE(General%20%20Compliance%20Training)/en-

US/ProductDetails_US/HACCP-training.aspx

20. http://ncsu.edu/foodscience/extension_program/haccp.html

21. http://foodipm.com/default.aspx

22. http://www.qualitysupportgroup.com/Our%20Services/FoodSafety_HAACP%20-

%20Our%20Services.html

23. http://www.econtrolsystems.com/foodsafety.html

24. http://www.fqcsolutions.com/HACCP.html

25. http://www.ehow.com/list_7222922_haccp-methods.html

26. http://www.foodnetconsultants.com/Consultancy_Services.php

27. http://www.fda.gov/Food/FoodSafety/HazardAnalysisCriticalControlPointsHACCP/HAC

CPPrinciplesApplicationGuidelines/default.htm

28. Hazard Analysis of Critical Control Points, Workbook by Markson, Inc.-800-528-5114

29. Syed, Tauqeer Haider (1995) TQM via ISO 9000 CDL Experience Pakistan ‘sIst

International Convention on Quality Control, Karachi 1995

30. Hussain, Asif (1996) Implementing ISO 9000/CGMP in Surgical Industry Pakistan’s

Second International Convention on Quality Control, Karachi 1996

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

ANNEXURES

ANNEXURE -1:

PRE-REQUISITE PROGRAMS:

Procedure-1: Establishment: Design & Facilities

Records: 1-Factory Layout

2-Some Basic Factory Information

Procedure-2: Glass Management & Hygiene Control System

Records: 1-Inspection report for management of glass;

2-Sanitizing Solution Concentration Record;

3-Discarded Product Record

Procedure-3: PRP-Store Management

Records: 1-Checklist for Receiving Goods

2-Checklist for Finished Goods

Procedure-4: PRP-Product Recall

Records: 1-Recall Team

2-Recalled Product Trace back Log

3-Recall Notification

4-Recalled Product Distribution

5-Recalled Product Corrective Action)

Procedure-5: PRP-Cleaning & Sanitizing

Procedure-6: PRP-Pest Control

Records: 1-Type of Pests & their Control

2- Functional Report of Pest Control Equipment

3-Pest Control Equipment Log Book

4-Spray Log Sheet

5-Observed Non-Captured Pest Log Book

Procedure-7: PRP-Monitoring Effectiveness

Records: 1-Pre-Operational Inspection Checklist

2-Monthly Maintenance Checklist

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

Procedure-8: PRP-Health Screening

Records: 1-Health Screening Report

Procedure-9: PRP for Reporting Employee Illness & Injury

Records: 1-Reporting Employees Illness & Injury

Procedure-10: PRP-Hand washing

Procedure-11: PRP-Personal Hygiene

Records: 1-Checklist of Personal Hygiene Facilities

Procedure-12: PRP for Visitors

Records: 1-Visitors Log Book

Procedure-13: PRP-Incoming Vehicle Inspection

Records: 1-Transport Contract

2-List of Contractors

3-Incoming Vehicle Inspection Checklist

Procedure-14: PRP-Product Information & Consumer Awareness

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

ANNEXURE -2:

HACCP TEAM

Name Position

Coordinator Management Representative

Other Team Members

CEO

Account & Purchase Manager

Maintenance Incharge

Production Incharge

Admin. & HR Officer

HACCP SUB TEAM

Name Designation Specialty in Hazard Type

CEO Microbiological & Chemical Hazard

Maintenance Incharge Physical Hazard

Production Incharge Physical Hazard

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

ANNEXURE -3:

PRODUCT DESCRIPTION & ITS INTEDED USE FOR FILM

PRODUCTNAME

IMPORTANTPRODUCT

PROPERTIES

HOW ITIS TO BE

USED

PACKAGING&

LABELLING

SHELF LIFE &STORAGE

CONDITIONS

WHEREIT WILLBE SOLD

CONSUMERINSTRUCTION

SPECIALDISTRIBUTION

CONTROL

WHITEOPAQUEFILM

FrictionReady touse as aprimarypackagingmaterialforlamination oftea bags,shampoobags, etc

Only stretchwrapping for

rolls < 50 Kgsand Card

board alongwith stretch

wrapping forrolls > 50 Kgs

1 year ShelfLife

M & F

Acclimatize for24 hours beforeuse or increaseuses temperatureto get thedesiredperformance

Appropriatevehicleensuring safetyfrom anyphysical,chemical orbiologicalhazardcontamination

ExtrusionProcess

< 300CStorageTemperature

PakPackages

LDPE basedAway fromSunlight

Dynamic

Sealing Al-Aziz

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

ANNEXURE -4:

PRODUCTION FLOW DIAGRAM FOR POLY BAG

Carry the required material for the assigned job with the help of lifter

The material passes through extruder, connector & then die in the form of bubble.And the bubble is maintained with the help of the air provided through the

compressor.

Transfer the tube towards bag making machine with the help of lifter

Load and pass the tube through the guiding rolls

Wrap the reel with stretch wrap

Unloading of material from the vehicle while stacking in the Store

Pass the film under the sealer

Take the material in the tub according to recipe and thentransfer to m/c hopper after mix it manually

Pass the film through the guiding rolls

Cut the film with the help of cutter

Pack the bags

Transfer the bag for weighing & then stacking on thepallets present in the stacking area with the help of lifter

Cover the bags with the poly film

Dispatching of material to customer through the contractor van

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

ANNEXURE -5:

ON SITE VERIFICATION OF FLOW DIAGRAM

Name Designation Signature

CEO

Management Representative

Maintenance Incharge

Production Incharge

Admin. & HR Officer

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

ANNEXURE -6:

HACCP – HAZARD ANALYSIS WORKSHEET:Pr

oces

sing

Ste

p

Iden

tify

pote

ntia

lH

azar

ds in

trod

uced

,co

ntro

lled,

or

enha

nced

, at t

his

step

Are

any

pot

entia

l foo

dsa

fety

haz

ards

sign

ific

ant?

(y

or n

) Risk Level

Just

ify

your

dete

rmin

atio

n of

haza

rd s

igni

fica

nce

Wha

t con

trol

mea

sure

sca

n be

app

lies

for

the

sign

ific

ant h

azar

d?

Are

the

pote

ntia

lha

zard

s, a

t thi

s st

epha

ve b

een

cont

rolle

d or

enha

nced

by

the

PRP’

s

Is th

is s

tep

a cr

itica

lco

ntro

l poi

nt?

(y o

r n)

1 2 3 4 5

The materialpasses throughextruder,connector & thendie in the form ofbubble. And thebubble ismaintained withthe help of the airprovided throughthe compressor.

Biological N

Chemical N

Physical Y

If the air tomaintainthe size ofthe bubble& passagefrom die towindingroll is notclean

There is nopre-requisiteavailable

Uncontrolled CCP

Wrap the reelwith stretch wrap

Biological Y

Due toDiseasedPersonnel

PRP forPersonnelHygiene,Reportingof Illness &Injury, &HealthScreeningareavailable.

Controlled N

Chemical NPhysical Y

Contamination due toImpropercaringwhilepacking thereel

PRP ofGlassmanagement &HygieneControlSystem andstoremanagement areavailable.

Controlled N

ICQI-Lahore, 2-3 May 2011ICQI-Lahore, 2-3 May 2011

ANNEXURE -7:

HACCP PLAN SUMMARY

ProcessSteps /CCP

HazardCriticalLimits

Monitoring Procedures CorrectiveAction

VerificationRecord

KeepingWhat How Freq. Who

Fill thebubblewith airto attaintherequiredsize

DustDustyAirFilters

Inspectionof the AirFilter

DailyMaintenanceIncharge

1-CCPundercontrol;2-Dispositionof non-complyingproduct;3-Causedcorrectedto preventarecurrence;4-Maintainthe record

1-AreaClean &Maintained;2-PersonalTrained; 3-Criticalrecordsaccurate &maintained

1-Allverificationrecords;2-AllcriticalfactorsRecording

Acknowledgement:We are thankful to Mr. Muhammad Hussain PhD CEO Express Pac (Pvt)

Ltd. who allowed us to share the data of ExpressPac to other companies as a

best management practice.