The

HACCP Training Resource Pack

Trainer's Manual

Sara Mortimore • Carol Wallace

Accredited by the International HACCP Alliance

Certificated by the Royal Institute of Public Health and Hygiene

AN ASPEN PUBLICATION Aspen Publishers, Inc.

Gaithersburg, Maryland 2001

Library of Congress Cataloging-in-Publication Data

Mortimore, Sara. The HACCP training resource pack: trainer's manual! Sara Mortimore, Carol Wallace.

p. em. Includes bibliographical references.

ISBN 0-8342-2075-X 1. Food-Microbiology. 2. Food-Safety measures. 3. Food industry and trade-Quality control. 4. Food

adulteration and inspection.!. Wallace, Carol. II. Title. QR115 .M643 2000 664'.001'579-dc21

00-063957

Copyright © 2001 by Sara Mortimore and Carol Wallace. All rights reserved.

Aspen Publishers, Inc., grants permission for photocopying for limited personal or internal use. This consent does not extend to other kinds of copying, such as copying for general distribution,

for advertising or promotional purposes, for creating new collective works, or for resale. For information, address Aspen Publishers, Inc., Permissions Department,

200 Orchard Ridge Drive, Suite 200, Gaithersburg, Maryland 20878.

For U.S. and other non-European orders: Orders: (800) 638-8437

Customer Service: (800) 234-1660

For European orders: Plymbridge Orders: orders@plymbridge.com

Plymbridge Customer Service: +44 (0) 1752 202301 cserv@plymbridge.com

About Aspen Publishers • For more than 40 years, Aspen has been a leading professional publisher in a variety of disciplines. Aspen's vast information resources are available in both print and electronic formats. We are committed to providing the highest quality information available in the most appropriate format for our customers. Visit Aspen's Internet site for more information resources, directories, articles, and a searchable version of Aspen's full catalog, including the most recent publications: www.aspenpublishers.com

Aspen Publishers, Inc. • The hallmark of quality in publishing Member of the worldwide Wolters Kluwer group

Editorial Services: Denise Hawkins Coursey Library of Congress Catalog Card Number: 00-063957

ISBN: 0-8342-2075-X

12345

Table of Contents

Foreword .......................................................... vii William H. Sperber

Foreword .......................................................... ix Roger Smith

Acknowledgments xi

How To Use The HACCP Training Resource Pack. . . . . . . . . . . . . . . . . . . . . . . . . xiii Introduction ............................................... xv Contents of the Resource Pack ................................ xvii Recommendations for Use of the Resource Pack . . . . . . . . . . . . . . . . . . XXI

Preparing and Planning for HACCP Courses . . . . . . . . . . . . . . . . . . . .. XXUI

Course Agenda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. xxxi Training Course Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxiii IHA, RIPHH, and Additional Training Objectives . . . . . . . . . . . . . . . .. xxxv Procedures for Registration of Examination Centers and Instructors

in HACCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. xliii

Module 0: Course Preliminaries ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Module 1: Introduction to HACCP ...................................... 7 1.1 Introduction ............................................ 8 1.2 HACCP Structured Approach .............................. 9 1.3 HACCP Background .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.4 HACCP Principles ....................................... 16 1.5 Benefits and Limitations .................................. 18

Module 2: NationallIntemational HACCP Standards-Relevance to Food Trade ............................................... . 2.1 Introduction ........................................... . 2.2 HACCP and International Trade ........................... .

1he HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

37 38 39

---III

2.3 Codex and Other Relevant Committees. . . . . . . . . . . . . . . . . . . . . . . 42 2.4 Legislative Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 2.5 HACCP Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Module 3: Preparing for HACCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3.1 Introduction ............................................ 58 3.2 Personnel and Training ................................... 59 3.3 Prerequisite Programs and Assessment of Current Status ........ 71 3.4 HACCP System Structure Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 3.5 Project Planning Techniques ............................... 88

Module 4: An Introduction to Hazards, Their Significance and Control . . . . . . . . 93 4.1 Introduction ............................................ 94 4.2 Hazard Typ.es and Their Significance ........................ 95 4.3 Understanding Control Points .............................. 108 4.4 Key Points Summary ..................................... 111

Module 5: Designing Safety into Products and Processes . . . . . . . . . . . . . . . . . . . . 113 5.1 Introduction ............................................ 114 5.2 Can It Be Made Safely? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 5.3 Intrinsic Factors ......................................... 116 5.4 Raw Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 5.5 Process Technologies ..................................... 119 5.6 Shelf Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 5.7 Product Safety Assessment ................................ 122

Module 6: Developing a HACCP Plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 6.1 Introduction ............................................ 134 6.2 Getting Started .......................................... 140 6.3 Product Descriptions ..................................... 146 6.4 Process Flow Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 6.5 Hazard Analysis and Control Measures ...................... 158 6.6 CCP Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 6.7 HACCP Control Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 6.8 Critical Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 6.9 Monitoring Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 6.10 Corrective Action Procedures ............................. 204 6.11 Validation of HACCP Plan Elements . . . . . . . . . . . . . . . . . . . . . . . . 214 6.12 Control Point Differentiation and Management ............... 217

Module 7: Implementation of a HACCP Plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

iv

7.1 Introduction ............................................ 222 7.2 Implementation Approaches ............................... 223 7.3 Training Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 7.4 Resources-Equipment and Facilities. . . . . . . . . . . . . . . . . . . . . . . . 233 7.5 Process Capability Assessment ............................. 236 7.6 Monitoring and Recordkeeping .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

Module 8: Verification and Maintenance of the HACCP System .............. 243 8.1 Introduction ............................................ 244 8.2 HACCP Verification Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 8.3 HACCP Audit Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 8.4 Data Review and Analysis ................................. 259 8.5 HACCP Maintenance-Managing Change. . . ... .. .. .. . . . . .. . . . 262

Module 9: Linking HACCP with Other Quality Management Techniques-Benefits of a Combined System ................................ 277 9.1 Introduction ............................................ 278 9.2 Management System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 280 9.3 HACCP and International Quality Management Standards ....... 281 9.4 Good Laboratory Practice Systems .......................... 287 9.5 Health and Safety Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 9.6 Environmental Management Systems ...................... . . 289 9.7 Planned Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 290 9.8 Sensory Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 9.9 Integrated Approach-Implementation Flow Diagram. . . . . . . . . . . 292

Module 10: Epilogue ................................................. 293 10.1 Introduction ........................................... 294 10.2 Food Industry Drivers of Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 10.3 Integrated Food Safety Management. . . . . . . . . . . . . . . . . . . . . . . . 296 10.4 Education and Training for Food Safety ..................... 297 10.5 HACCP-Critical Success Factors. . . . . . . . . . . . . . . . . . . . . . . . . . 298

Glossary 301

Acronyms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

References and Further Reading ....................................... 309

Index to Exercises, Team Activities, and Slides ........................... 313

Trainer's Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. v

Foreword

Since its inception over 30 years ago, the HACCP system of food safety has gradually evolved to its current state of refinement. The original HACCP system was based on three principles. While it represented a significant advance over the conventional qual­ity control approach for food safety in use at that time, the original HACCP system was not without its own shortcomings, which were painfully revealed in a number of food safety failures. The shortcomings were usually errors of omission related to the absence of specific requirements for the effective management of critical control points, for example, requirements for critical limits, corrective actions, verification, and documentation. Food safety professionals at many companies and agencies around the world worked to develop the necessary requirements. As a result, the HACCP system was expanded to its current seven principles. The HACCP system of food safety is now understood and required or recommended by food processors, public health officials, and food regulators worldwide. The form of the modern HACCP system was perhaps best articulated in the 1994 publication, HACCP: A Practical Approach, by Sara Mortimore and Carol Wallace (a second edition, published in 1998, forms part of this pack).

Early HACCP development and refinement focused on establishment of the HACCP principles. Having accomplished that, many food companies and food safety profession­als recently came to realize that more attention must be given to proper implementation and maintenance of HACCP systems in their food plants. This point is of utmost importance if HACCP is to be used effectively for food safety assurance in global commerce. Fortunately, the authors, Sara Mortimore and Carol Wallace, have continued their good work with the publication of The HACCP Training Resource Pack. In addi­tion to addressing the important aspects of HACCP principles and HACCP studies, it provides a very thorough treatment of HACCP implementation and maintenance.

The HACCP Training Resource Pack is a complete compilation of materials that a HACCP trainer would need, with suggestions for adaptations for diverse audiences ranging from line workers to senior management. The pack consists of the trainer's manual, trainee course notes, PowerPoint slides, and various forms and supplemental documents, provided in hard copy and/or on a CD-ROM. The pack also includes the

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. vii

book HACCP: A Practical Approach (2nd edition), and HACCP: How the System Works, a videotape. The layout of the trainer's manual features an innovative design that will make it easier for the trainer to present this program. It is obvious from the organization of this pack that the authors are not only food safety experts, but also training experts.

HACCP is an effective process in which food safety is designed into the product and the process by which it is produced. Therefore, the two fundamental areas in a HACCP study that require detailed attention are product design and process control. Some food companies have focused predominantly on one of these areas. As a result, they have developed unbalanced or incomplete HACCP Plans. The HACCP Training Resource Pack can help avoid or remedy this inadequacy because it provides a balanced treatment of both product design and process control.

The authors have globalized the information in The HACCP Training Resource Pack, so that it does not unduly favor one geographic region. This information meets all of the training requirements of the International HACCP Alliance and the Royal Institute of Public Health and Hygiene, and, I suspect, of most, if not all, advisory and regulatory bodies worldwide.

It is generally recognized that there is a shortage of HACCP experts who can provide assistance and training to the hundreds of thousands of food plants around the world. The availability and use of The HACCP Training Resource Pack will improve this situation by placing well-organized tools and information in the hands of HACCP trainers.

viii The HACCP Training Resource Pack

William H. Sperber, PhD Cargill, Inc.

Wayzata, Minnesota

copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

Foreword

New policies or novel techniques remain the exclusive province of decision makers and developers until they have been satisfactorily communicated to those who must imple­ment them. When new government regulations or company policy statements require radical changes to well-established methods and procedures, the publication of these methods and procedures alone is seldom enough to ensure satisfactory implementation. Successful transition can be frustrated by those who perceive no need to change the old order and by others who cannot comprehend the new. The development and introduction of HACCP provides this kind of challenge. The training provider plays the indispensable role of ensuring that the message is understood and implemented correctly. Wise policy makers and food authorities include this essential function in their planning.

HACCP is not new to those who have been shaping safety and quality management systems in the foremost food companies. The World Health Organization (WHO) Food Safety Unit and the WHO/Food and Agriculture Organization Codex Alimentarius Commission have also played indispensable global leadership roles in improving food safety and management practices. Therefore, it was only a matter of time before HACCP principles were written into food safety policies worldwide. By the mid 1990s, the implementation of HACCP systems had become a requirement in Europe. Yet govern­ments were reluctant to indicate for training providers acceptable levels of skill and knowledge.

An understanding and acceptance of standards is of paramount importance to auditors and inspectors, especially across national boundaries. Global standards of training in food safety and the principles of its efficient management, based upon science and HACCP, could achieve much for the long-term development of internationally agreed food safety standards. However, in the absence of clear central guidelines at the national level, the provision of HACCP training of variable quality can grow uncontrolled. For example, the U.S. Department of Agriculture/Food and Drug Administration Foodborne Illness Education Center currently devotes 76 Web pages to available HACCP training programs. Significantly, it takes care to avoid endorsing their standards or quality.

The HACCP Training Resource Pack . Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. IX

It was inevitable that the vacuum would be filled. In the United Kingdom, the HACCP Training Standards Steering Group, a group of leading HACCP experts from across the food industry and food research associations working with the food authorities and training designers, developed training standards for adoption by any food industry sector. The U.K. Food Standards Agency now recognizes these training standards and encourages training providers to design courses that conform to them. Similarly, in the United States, the International HACCP Alliance has set out to become the worldwide HACCP authority. Both bodies now offer food authorities and regulators, food safety inspectors, and auditors benchmarks against which to assess standards of training.

Food safety management faces two major training challenges. First, it is essential to re-educate those who carry out the training, both formally and on the job. For decades, practitioners have believed that food safety can be ensured only by strict codes of hygienic practice confirmed by end testing. Now they must learn the radical notion that, although hygienic working methods remain essential, some time-honored practices may not be needed. Moreover, they must appreciate that food safety can be more cost effectively achieved and a work force can be better motivated using modern techniques.

The second challenge is encouraging busy training providers to develop new training materials. Course development is time-consuming work. Ideally, trainers need to know the required minimum content of their courses-the standard. They need a source of in-depth knowledge for themselves, including notes on how best to put across the new concept, together with training aids to reinforce their teaching.

The HACCP Training Resource Pack meets the needs of training providers admirably. The Trainer's Manual provides in-depth coverage of the methodology and its underlying science. The training notes and course content conform to the published HACCP train­ing standards and offer an exhaustive library of teaching materials. This pack gives training providers the means to construct HACCP courses that satisfy their clients' requirements at the recognized standards.

x

Roger Smith Chairman

HACCP Training Standards Steering Group London, United Kingdom

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

Acknowledgments

Thanks are extended to Pillsbury Europe (formerly Grand Metropolitan Foods Europe) and Reading Scientific Services, Ltd. (RSSL) for permission to reproduce a number of materials within this training course.

Sara Mortimore and Carol Wallace, 2001

Disclaimer The material presented in this training program is presented after the exercise of care in its compilation, preparation, and issue. However, it is provided without any liability whatsoever in its application and use. The contents reflect the personal views of the authors and are not intended to represent those of The Pillsbury Company, Reading Scientific Services, Ltd., or their affiliates.

1be HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xi

INSERT

How To Use The HACCP Training

Resource Pack

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

---XIII

Introduction

These training materials have been based on the highly acclaimed HACCP: A Practical Approach, 2nd ed. (Mortimore and Wallace 1998) and meet the requirements of both the UK HACCP Training Standards (Introductory and Advanced), published by the Royal Institute of Public Health and Hygiene (RIPHH) on behalf of the UK HACCP Train­ing Standards Steering Group and acknowledged by the World Health Organization's Food Safety Unit, and the International HACCP Alliance (iliA) in the United States.

The aim of this pack is to provide you, the trainer, with all the materials necessary to conduct comprehensive HACCP training courses, leading the trainees through the development of successful HACCP programs.

No prior knowledge of HACCP on the part of the trainee is assumed. However, a basic foundation in food safety, sanitation, and hygiene principles would be advantageous (for example, the level of knowledge provided by the RIPHH First Certificate in Food Safety or equivalent).

There are a number of ways in which you may wish to use this material: you may have a requirement to conduct in-house training courses, or you may be a training consultant wishing to add a recognized HACCP course to your portfolio. The materials are flexible, allowing you to design your own program depending on training needs, ranging from an overview of HACCP to an in-depth application of the HACCP principles.

The HACCP Training Resource Pack consists of (1) the Trainer's Manual; (2) a CD-ROM containing files for the text of the Trainer's Manual, the Trainee Course Notes, Power­Point slides that appear in the Trainer's Manual, a summary booklet titled HACCP: Your Questions Answered, Resource Materials, and Course Masters; (3) HACCP: A Practical Approach (2nd ed.); and (4) HACCP: How the System Works, a video created by Reading Scientific Services, Ltd.

We would be delighted to receive feedback and suggestions on how the materials could be improved. You can e-mail usathaccp.bluebook@btinternet.com.

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xv

Contents of the Resource Pack

TRAINER'S MANUAL

This Trainer's Manual is divided into three sections:

• How To Use The HACCP Training Resource Pack • The Training Program • Appendixes

It is recommended that you familiarize yourself with all of the information before planning your training program.

The Training Program consists of "Module 0: Course Preliminaries" followed by 10 training modules. The Appendixes section contains a glossary, a list of acronyms and their definitions, a reference and suggested readings list, and index to exercises, team activities, and slides, and blank pages where you can add your own notes and anecdotes.

An illustration of the Training Program layout follows. The format of the course material is consistent throughout the modules.

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xvii

The current slide is reproduced here. This will enable you to talk to the trainees and not to the projector screen.

"Trainer:" fol­lowed by text in italic type­face indicates a "doing" . action.

"Key Points" followed by text in standard typeface pro­vides addi­tional prompts as to the key messages to be relayed for this slide.

CD-ROM The CD-ROM contains

Module number Topic number

Module 1 !.~._ .. !YIC::C::I'_~!!!I.__ _____ . __ ... _____ ... ______ ..

Slidcl-S

Reference: Chapter '1, HAGep: .4 Pmctit;lI]

Approach, 2nd cd.

Trainer: A,<iK l}w lroj1lf!t;_'t lor some sympJollls offoor/ poisoning f/lipchaft!. COllMdm' Hw outcome in zero grovity!

Key Points • HACCP origillUlml in :1959 as part of the U.S. manrwd spau~ progrnUl.

• The PiJlsblll'Y Cll. workod with NASA and t.::.5. Army lalmrai,orle~.

• it fm;ognized that traditional quatity cont.rol methods (ill$tlection and t{~stillg) didn"t give enQugh a$SUr,mCl~ of product sufl'!t.\'.

• It is ba~ed ,)U tho \>ngiuccring sysh~m Eailun~ Modo and Efteel ~j..na!ysi" (FMEA).

• It was shared \vitt! !lH~ fnmi iudtls!r.1i' and mgulfltnry ngenl.::i{!5 in 197J in the l.lnited St,)t(l$.

• It hos OfJ!_m adopted and dtwl~loped hy s\wvrni ct1mpanit~s and progrHssl~d armmd th~w()rI.d,

FolloWing slide:

12 "/he HACCP Tmining IIesooroe Pack C(!!)VriJ;h~ *) ZOH1 i)aru; Mo;1:imnn' 1.- Card W<!llil<xl ! l'B~Ii~!lt'd by Asp'w i-'ublilJhm-!;. inc.

• text of Trainer's Manual • Trainee Course Notes • Microsoft PowerPoint slides that appear in the Trainer's Manual • HACCP: Your Questions Answered • Course Masters • Resource Materials

It allows trainers to

The number of the slide appears to the top right of each reproduced slide. Numbering is by module and by slide: e.g., "Slide 1-4" indi­cates Module 1, fourth slide.

References to HACCP: A Prac­tical Approach (2nd ed., 1998) and other resources will be indicated here. This will enable you to locate the section within the book and make more detailed notes if required.

A reduced-size "following slide" is located here. This will help to remind you of what comes after the current slide.

• access slides for each module/part module as required for the training session • print out slides for each module/part module

xviii The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

• print out paper copies of master forms and exercises for use in training sessions • produce the required handout sections for each session

Trainee Course Notes

Trainee Course Notes can be printed, copied, and handed out to trainees. They consist of support material for each module of the training course. Each handout has been designed to allow the trainee to add his or her own notes.

These materials are sufficiently detailed for trainees wishing to take examinations at the end of training, such as the RIPHH examinations in HACCP principles and/or play an active role in the development and implementation of HACCP systems. How­ever, we recommend that, for maximum development and understanding, copies of HACCP: A Practical Approach (2nd ed.) be given to all trainees. As a registered purchaser of this course, you are entitled to receive additional copies of the book at a discount. Please contact Special Sales Unit, Aspen/Plymbridge at 301-417-7591 or lmckenna@aspenpubl.com.

PowerPoint Slides

For your convenience, slides can be accessed by module, and within each module individual slides can be accessed and printed.

HACCP: Your Questions Answered

HACCP: Your Questions Answered is a summary booklet that can be printed and copied as handout material for trainees who require only an overview of HACCP and not detailed information (for example, persons undergoing operator-level training or senior management briefing).

Course Masters

Within this file, you will find a blank name card, a training certificate master, and a sug­gested course evaluation questionnaire. Also provided are blank HACCP documentation forms (Industrial Product Safety Assessment form, Hazard Analysis Chart, CCP Decision Tree Record sheets, HACCP Control Chart, HACCP and Quality Control Chart, HACCP Audit Checklist, and HACCP Noncompliance Note). These may be printed and copied and given to trainees in the full course.

Resource Materials

The Resource materials section of the CD-ROM contains primary resources that can be printed and handed out to trainees or used as reference material for the trainer. Within this file you will find Hazard Analysis and Critical Control Point Principles and Application Guidelines (NACMCF); 21 CFR 123: Fish and Fishery Products; 9 CFR 304: Meat and Poultry HACCP Regulation; Guidelines for Developing a Standard Operating Procedure for Sanitation (Sanitation SOP's) in Federally Inspected Meat and Poultry Establishments (FSIS-USDA HACCP Regulation); Recommended International Code of Practice General Principles of Food Hygiene [CAC/RCP 1-1969, Rev. 3 (1997), Amd. (1999)]; and 21 CFR 110: Current Good Manufacturing Practice in Manufacturing, Packing, or Holding Human Food.

The HACCP Training Resource Pack . Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. XIX

HACCP: A PRACTICAL APPROACH (2nd Ed.) This book provides a thorough and detailed guide to HACCP application and is essential reading for all HACCP trainers. The Trainer's Manual cross-references relevant sections, but it is recommended that trainers become familiar with the entire book before running the course.

HACCPVIDEO

HACCP: How the System Works is an introductory video designed for use in awareness training situations. This is an added-value portion giving the trainer the materials to train the whole work force.

The video is designed to provide a general introduction to the HACCP system and will help HACCP teams and trainers get the message across to the whole work force when implementing HACCP into everyday practice. It will enable everyone in an organization to understand how HACCP relates to them and the important role they play in ensuring safe food production.

To help you personalize the presentation for your own training program, the video can be paused in a number of locations, allowing further information to be inserted or discussion to be initiated. These locations are denoted by short musical/caption sequences and can easily be found during preparatory viewing.

HACCP: How the System Works has been produced as a venture between RSSL and Shield Video Training Ltd. The companies bring together considerable experience in the fields of HACCP training and the production of audiovisual training products for the food industry.

The HACCP Training Resource Pack xx Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers. Inc.

Recommendations for Use of the Resource Pack

The training materials have been designed for use as a complete training program, but they allow you flexibility in planning your own training sessions. If you are planning to use the complete course and use the RIPHH examinations in HACCP principles (Introductory or Advanced levels) as a measurement of training effectiveness, there are several ways of structuring the program.

Although the full program will give a detailed understanding of HACCP applications, it is recognized that different groups of trainees will have different training needs. The following table outlines the suggested variations from the complete course.

Course-structuring Suggestions

HACCP:Your Trainees Questions

1 2 3 4 5 6 7 8 9 10 Course Notes Answered

HACCP team members + + + + + + + + + + +

New product development personnel + + + + + + + + + + +

Supplier quality assurance personnel + + + + + + + + + + +

Senior management + + 0 0 0 0 0 0 + + 0 +

CCP monitors + + 0 0 0 0 0 0 +

Supervisors + + 0 0 0 0 0 0 +

Work force + 0 +

Key: +, recommended; 0, optional addition; -, not essential.

For those training sessions that are designed to provide an overview, you may wish to consider using the video and supplementing Modules 1 and 2 with an exercise such as Exercise 4 in Module 7.

The HACCP Training Resource Pack . Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. XXI

Preparing and Planning for HACCP Courses

Because the HACCP technique is a fresh way of thinking and working, trainees need to assimilate new and challenging concepts. Therefore, careful preparation of the teaching session is vital. This should be backed up by the ability to relate the new ideas to the practical experience of implementing HACCP.

The following guidelines on preparing and planning for HACCP courses are designed to assist trainers in getting maximum use of the resource pack.

TRAINER PREPARATORY GUIDELINES

Before running any training session using these materials, you will need to

• Read HACCP: A Practical Approach (2nd ed.). This book provides a comprehen­sive treatment of the HACCP principles and addresses all elements of the course. The Trainer's Manual cross-references to relevant chapters, enabling you to cross-check information quickly during training sessions. The book also provides additional materials that you may wish to incorporate into your training program.

• In addition, u.s. trainers should read HACCP: User's Manual by Donald A. Corlett, Jr. (Gaithersburg, MD: Aspen Publishers, Inc., 1998). The International HACCP Alli­ance Program requires significantly greater emphasis on meat and poultry, plus Sanitation Standard Operating Procedures (SSOPs). The course material will cross­reference to HACCP: User's Manual where additional detail is helpful.

• Fully familiarize yourself with the training materials. The Trainer's Manual should be supplemented with your own examples and anecdotes.

• Obtain a number of other publications. In preparation for the training delivery, you may wish to refer to key documents such as the Codex Alimentarius HACCP document, National Advisory Committee on Microbiological Criteria for Foods (NACMCF) documents, relevant HACCP Training Standards, or relevant legislation, some of which are provided in the Resource Materials section of the CD-ROM included in this pack. There are also a number of useful World Health Organization (WHO) guides, such as Training Considerations and Aspects for the Application of the HACCP System to Food Processing and Manufacturing (WHOIFNU/FOS/93.3

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xxiii

and WHO/FNU/FDS/96.3) and Codex Alimentarius Food Hygiene Basic Texts, which contains the Codex HACCP document along with materials on general principles of good hygiene and principles for the establishment and application of microbiological criteria for food.

• Attend relevant training courses, such as trainer training, if you have not already done this, and/or a course leading to introductory/advanced HACCP examinations (e.g., RIPHH in the UK) if you are planning to use examinations with your trainees.

TEAM ACTIVITIES AND EXERCISES Aim: To give trainees practical experience using the HACCP Principles, developing a HACCP Plan, and discussing implementation and maintenance activities.

This course contains a number of classroom exercises and team activities. The class­room exercises involve the whole class and are led by you, the trainer, as part of the overall teaching of the course. The team activities are an opportunity for the class to break into groups and to learn by experience and by applying what they have learned. The outputs from these team activities are accumulated throughout the course as a coherent HACCP Plan.

All classroom exercises and team activities used in the program are situated within the Trainer's Manual and include instructions on how to facilitate them. However, it is strongly recommended that you produce your own versions, drawing upon examples that are relevant to your particular audience. The exercises and activities contained within the course can provide a framework to enable you to generate your own ideas. For example, if you are using the course in a food service context, then the message will be best delivered through the use of a food service example. The example provided in the pack (Chicken Burger) was chosen because it can be used for manufacturing or food service. However, trainers are encouraged to develop their own materials.

Although the course has been built around the food industry, the HACCP concept can be used effectively for control of hazards during the production of nonfood items or to provide a structured approach to health and safety management. In these cases, use of appropriate, self-generated examples during the team activities is highly recommended.

How the Activities Work The activities are interspersed through the course modules. They are based on working with an example product through the HACCP process so that trainees continually build on the work of their teams, while applying the HACCP principles and learning useful techniques to help them set up their own HACCP systems back in the workplace.

The sample product used should depend on the group to be trained. An outline for a chicken burger product is provided. Alternatively, another example can be chosen, such as a sandwich. It is preferable that the example chosen have relevance to the group being trained. Each team may be given a slightly different angle to work from-large manufacturer, small processor, catering operation, and so on-so that the ways of approaching and applying HACCP to different types of businesses are thoroughly discussed.

. The HACCP Training Resource Pack XXIV Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

In preparation for the team acti vi ties, trainees are divided into teams of four to six people, using their backgrounds to achieve a spread of expertise. Make sure that you consider this in advance. Details of team members should be written on a flip chart or slide before the first team activity is introduced to allow trainees to readily see which team they are in. Ideally, each team should be given a separate room to work in, but if space is a problem, then teams should be positioned together within the training room.

Materials Needed for Each Team

• Flipchart, easel, and pens for developing ideas • Tacks, reusable adhesive, or tape to post flip chart pages around the room • Dry erase board, blank overhead transparencies, and appropriate pens (optional).

Introducing Team Activities

After the details of each team activity have been introduced, trainers should

• Check that everyone understands the activity, and take any questions about the activity.

• Provide copies of relevant documentation/forms for each team. • Explain that the trainer(s) will be spending time with each of the groups to facilitate

the exercise. Confirm the time duration for the exercise and the time at which the group will reconvene for the feedback session.

During the Team Activity

Encourage the teams as they work through each activity, providing clarification, promot­ing understanding, and answering questions.

Feedback from the Team Activity

Ask the spokesperson from each team to confirm briefly the team's findings. Where several teams are working on the same exercise, it may be more appropriate to require feedback in terms of learning points rather than technical detail.

WARNING: The outputs of most team activities are used as the basis of the next team activity [i.e., B builds on A, C builds on B, etc.). Do not allow trainees to throw their materials away!

COURSE PREPARATION

Handout Materials

Handout materials can be printed and copied from the files provided on the CD-ROM. The following handouts are provided.

1. From the file "Trainee Course Notes": supplementary notes and exercise details for each module. These can be printed and copied and placed in a three-ring binder.

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. XXV

2. The PowerPoint slides for each module, which can also be printed. 3. From the file "HACCP: Your Questions Answered": a summary booklet. If you

are running a briefing session, this booklet may be sufficient. It will need to be printed and copied.

4. From the file "Course Masters": a course attendance certificate, a blank name card, and a suggested course evaluation questionnaire. The latter will need to be printed and copied for each trainee. This may not be necessary when running a briefing session only.

5. From the file "Resource Materials": documentation from various regulatory agen­cies, which can be printed and handed out if appropriate for your trainees

Session Plan The session plan that follows details the materials required when presenting each module. It also indicates approximate total running times for each module, set of topics, and team activities. It should be used as a guide to develop your own specific agenda(s).

xxvi The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

SESSION PLAN

Module Subject Materials Required Time Guideline

0 Course Preliminaries Name tags. agenda. equipment to display slides. 30 minutes flip chart and pens

-------- -------------------- ------------------------------ -------------------1 Introduction to HACCP Equipment to display slides. flipchart and pens. 1 hour and 45 minutes (total)

Topic 1.1 Introduction decks of cards-doctored (one per pair of Topic 1.2 HACCP Structured Approach trainees). video and player (if being used). Topic 1.3 HACCP Background copies ofreference standards (e.g .• Codex. Topic 1.4 HACCP Principles NACMCF) Topic 1.5 Benefits and Limitations -------- -------------------- ------------------------------ -------------------

2 National/International Equipment to display slides. flip chart and pens 40 minutes (total) HACCP Standards-Rele-vance to Food Trade

Topic 2.1 Introduction Topic 2.2 HACCP and International

Trade Topic 2.3 Codex and Other Relevant

Committees Topic 2.4 Legislative Requirements Topic 2.5 HACCP Certification -------- -------------------- ------------------------------ -------------------

3 Preparing for HACCP Equipment to display slides. flip chart and pens 1 hour (total) Topic 3.1 Introduction Topic 3.2 Personnel and Training Topic 3.3 Prerequisite Programs and

Assessment of Current Status Topic 3.4 HACCP System Structure

Options Topic 3.5 Project Planning Techniques -------- -------------------- ------------------------------ -------------------4 An Introduction to Hazards. Equipment to display slides. flipchart and pens 1 hour (total)

Their Significance and Control

Topic 4.1 Introduction Topic 4.2 Hazard Types and Their

Significance Topic 4.3 Understanding Control

Points Topic 4.4 Key Points Summary --------- -------------------- ------------------------------ -------------------

5 Designing Safety into Products Equipment to display slides. flipchart and pens 1 hour and 45 minutes (total) and Processes

Topic 5.1 Introduction Topic 5.2 Can It Be Made Safely? 45 minutes (Topics) Topic 5.3 Intrinsic Factors Topic 5.4 Raw Materials Topic 5.5 Process Technologies Topic 5.6 Shelf Life Topic 5.7 Product Safety Assessment Break-out room for each team with blank Prod- 1 hour (Exercise)

Optional Exercise: Product uct Safety Assessment forms (paper or over-Safety Assessment head transparencies) and appropriate pens

continues

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xxvii

Module Subject Materials Required Time Guideline

6 Developing a HACCP Plan Equipment to display slides, flipchart and 9 hours (total) Section A pens-for all sections

Topic 6.1 Introduction 1 hour (Topics) Topic 6.2 Getting Started Topic 6.3 Product Descriptions Topic 6.4 Process Flow Diagrams

Team Activity A: Process Break-out room for each team with flipchart 1 hour and 30 minutes Flow Diagram and pens, and exercise instruction sheets (Activity)

--------- -------------------- ------------------------------ -------------------Section B

Topic 6.5 Hazard Analysis and Control 45 minutes (Topic) Measures

Team Activity B: Hazard Break-out room for each team with blank 2 hours (Activity) Analysis Hazard Analysis Chart (paper or overhead

transparencies) and appropriate pens, and exercise instruction sheets

--------- -------------------- ------------------------------ -------------------Section C

Topic 6.6 CCP Identification Break-out room for each team with blank CCP 30 minutes (Topic) Team Activity C: CCP Identi- Decision Tree Record sheets (paper or overhead 1 hour and 30 minutes

fication transparencies) and appropriate pens, flipcharts (Activity) and pens. and exercise instruction sheets

-------- -------------------- ------------------------------ -------------------Section D

Topic 6.7 HACCP Control Charts 45 minutes (Topics) Topic 6.B Critical Limits Topic 6.9 Monitoring Procedures Topic 6.10 Corrective Action Procedures

Team Activity D: Completing the Control Chart Break-out room for each team with blank 1 hour (Activity)

Topic 6.11 Validation of HACCP Plan HACCP Control Charts (paper or overhead Elements transparencies) and appropriate pens

Topic 6.12 Control Point Differentiation and Management

-------- -------------------- ------------------------------ -------------------7 Implementation of a HACCP Equipment to display slides 1 to 2 hours (total)

Plan Topic 7.1 Introduction 30 minutes (Topics) Topic 7.2 Implementation Approaches Topic 7.3 Training Requirements Topic 7.4 Resources-Equipment and

Facilities Topic 7.5 Process Capability Assess-

ment Topic 7.6 Monitoring and Recordkeep-

ing Flipcharts and pens 30 minutes to 1 hour and 30 Optional Exercise-HACCP minutes (Exercise)

Overview

continues

xxviii The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

Module Subject Materials Required Time Guideline

8 Verification and Maintenance Equipment to display slides 2 hours and 40 minutes (total) of the HACCP System

Topic 8.1 Introduction 1 hour (Topics) Topic 8.2 HACCP Verification Over-

view Topic 8.3 HACCP Audit Techniques Topic 8.4 Data Review and Analysis Topic 8.5 HACCP Maintenance-Man-

aging Change Team Activity E: HACCP Break-out room for each team, flip charts and 40 minutes (Activity)

Implementation and Main- pens tenance

Team Activity F: HACCP Break-out room for each team, with blank 1 hour (Activity) Compliance-Audit Check- HACCP Audit Checklist form (paper or over-list head transparencies) and appropriate pens,

flip chart and pens -------- -------------------- ------------------------------ -------------------

9 Linking HACCP with Other Equipment to display slides, flipchart and pens 1 hour and 15 minutes (total) Quality Management Tech-niques-Benefits of a Com-bined System

Topic 9.1 Introduction Topic 9.2 Management System Require-

ments Topic 9.3 HACCP and International

Quality Management Stan-dards

Topic 9.4 Good Laboratory Practice Sys-tems

Topic 9.5 Health and Safety Systems Topic 9.6 Environmental Management

Systems Topic 9.7 Planned Preventative Mainte-

nance Topic 9.8 Sensory Evaluation Topic 9.9 Integrated Approach-Imple-

mentation Flow Diagram

-------- -------------------- ------------------------------ -------------------10 Epilogue Equipment to display slides 30 minutes

Topic 10.1 Introduction Topic 10.2 Food Industry Drivers of

Change Topic 10.3 Integrated Food Safety Man-

agement Topic 10.4 Education and Training for

Food Safety Topic 10.5 HACCP-Critical Success

Factors

This course has been designed to enable a flexible approach with regard to running order. However, typically the Introductory level course would be run over a 2- to 3-day period and the advanced level over a 3 to 5 day period, each as a series of ten modules. Courses could be spread over a longer period (e.g., 1 day per week over a 3 week period). The trainer is advised to structure the course to fit the needs of the trainees and to adjust the technical depth as appropriate for introductory or advanced level training.

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xxix

Course Agenda

A detailed agenda needs to be developed and presented to trainees prior to the course. We have designed a flexible resource pack, allowing you to plan your own training course. The Session Plan can be used to determine approximate timing for each module.

The following points can be made when discussing the agenda with trainees:

• The team activities will give trainees the opportunity to apply the aspects of HACCP theory that they have just learned.

• Trainees should use the team activities to check understanding. Again, encourage trainees to ask questions if they have problems.

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xxxi

Training Course Checklist

As a final reminder, check the following actions before the start of the course:

.I Confirm trainee list. (Note: The number of trainees will depend on the number of trainers available, but as a guide a class size of no more than 12 is recommended.)

.I Send out complete and detailed instructions to trainees indicating location, start times, and course content.

.I Organize all food service requirements (refreshment breaks, coffee, lunch, dinner, etc.) .

.I Order RIPHH examination papers where required (four weeks before the examina­tion date) .

.I Familiarize yourself with the modules that you are about to present.

.I Print and photocopy trainee handout materials where required, using masters pro­vided .

.I Print and photocopy HACCP: Your Questions Answered .

.I Organize the training room and break-out rooms:

• Training room layout-V-shape recommended • Flipchart and paper • Flipchart pens • Blank overhead transparencies and appropriate pens (optional) • Equipment to display slides-is it working and are spare bulbs available, if

appropriate? • Determine how room lighting can be adjusted for displaying slides. • Decks of cards (one per two people), with jokers and aces removed. This is for

Exercise 2 in Module 1. • Video and video player • Microphone system, if needed • Determine how room temperature can be adjusted for participant comfort .

.I Identify team composition for team activities.

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xxxiii

IHA, RIPHH, and Additional Training Objectives

MEETING THE REQUIREMENTS OF THE INTERNATIONAL HACCP ALLI­ANCE (UNITED STATES): INTRODUCTORY MEAT AND POULTRY HACCP TRAINING COURSE

The following demonstrates where material can be found in the training resource pack that meets the requirements of the training standards. Trainers must review the individual training standards and select appropriate modules or topics for their planned training programs.

Training Objective

1. Recognize the relationship between RACCP and food safety.

1.1. Explain the relationship between RACCP and food safety.

1.2. Discuss the benefits of implementing a RACCP system, which include motivating and selling the industry on RACCP and reviewing case studies.

1.3. Discuss RACCP and basic food safety principles.

1.4. Review what students will learn from the course.

2. Review Good Manufacturing Practices (GMPs; not a part of the RACCP Plan).

2.1. Define and develop standard operating procedures (SOPs).

2.2. Define and develop GMPs.

2.3. Discuss the importance of SOPs and GMPs.

2.4. Describe how development of SOPs and GMPs is necessary before developing a RACCP Plan.

The HACCP Training Resource Pack

Location of Material in Pack

Module 1

Module 3

Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xxxv

Training Objective

3. Identify and control hazards.

3.1. Identify food items that are produced.

3.2. Define a hazard(s).

3.3. Name the three hazard categories (biological, chemical, physi­cal) as defined by the National Advisory Committee on Micro­biological Criteria for Foods (NACMCF).

3.4. Determine the significant hazards as described in Principle 1 of the NACMCF guidelines.

3.5. Explain control measures that prevent, reduce, or minimize hazards associated with foods.

4. Present and discuss the principles of HACCP.

4.1. Develop a flowchart of the process and product.

4.2. Conduct a hazard analysis; prepare a list of steps in the process where significant hazards occur, and describe the preventative measures.

4.2.1. Describe product and intended use.

4.2.2. Identify potential hazards at points where they enter the process/food or can be enhanced during the process.

4.2.3. Evaluate the severity and risk of hazards.

4.2.4. Document rationale for hazard selection.

4.2.5. Differentiate significant from nonsignificant hazards.

4.3. Identify critical control points (CCPs) in the process.

4.3.1. Define control point and critical control point.

4.3.2. Identify CCPs by using valid scientific criteria (Le., a decision tree).

4.4. Establish critical limits for preventative measures associated with each CCP.

4.4.1. Define and determine critical limits and operational limits.

4.4.2. Set critical limits that are relevant to product safety.

4.4.3. Document the rationale for critical limit selection.

The HACCP Training Resource Pack

Location of Material in Pack

Module 4

Module 6

Module 6

Module 6

Module 6

Module 6

xxxvi Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

Training Objective

4.4.4. Measure and document critical limits.

4.4.5. Explain how critical limits are used to measure compli­ance within a HACCP Plan.

4.5. Establish CCP monitoring requirements and procedures for using the results of monitoring to adjust the process and main­tain control.

4.5.1. Recognize the importance of monitoring.

4.5.2. Identify factors to be monitored.

4.5.3. Identify where measurements will be taken.

4.5.4. Explain how monitoring is to be conducted.

4.5.5. Determine the frequency for taking measurements.

4.5.6. Identify who is responsible for monitoring.

4.5.7. Describe monitoring procedures, sampling plans, and methodology used.

4.5.8. Clarify the difference between monitoring and verifica­tion.

4.6. Establish corrective actions to be taken when monitoring indi­cates that there is a deviation from an established critical limit.

4.6.1. Develop corrective actions.

4.6.2. Identify responsible authority for determining corrective action.

4.6.3. Describe corrective actions in SOP documentation that are consistent with monitoring activities.

4.6.4. Document corrective actions.

4.7. Establish effective recordkeeping procedures that document the HACCP system.

4.7.1. Discuss the importance of record keeping for determining the effectiveness of the HACCP system and for docu­menting appropriate efforts to produce safe food.

4.7.2. Identify what information should be included in records.

4.7.3. Develop records for documenting HACCP activities.

The HACCP Training Resource Pack

Location of Material in Pack

Module 6

Module 6

Module 7

Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xxxvii

Training Objective

4.7.4. Develop simple, plant-friendly records with clear instructions to be accessible at line worker level.

4.7.5. Recognize the importance of reviewing records before control of product is lost.

4.8. Establish procedures for verification that the HACCP system is working correctly.

4.8.1. Recognize the importance of verification to support and ensure the long-term viability of HACCP in an organiza­tion.

4.8.2. Discuss different activities that can be conducted as part of verification.

4.8.3. Reinforce the importance of record review before the control of a product is lost.

4.8.4. Implement a HACCP Plan review at regular intervals or when significant changes in equipment, ingredients, or operating procedures occur.

5. Implement a HACCP Plan.

5.1. Describe the commitment from upper management necessary for food safety to succeed.

5.2. Determine the key factors for successful HACCP implementa­tion.

5.3. Discuss the steps for developing and implementing HACCP in the production plant.

5.4. Develop implementation steps using GMPs as a foundation for HACCP.

5.5. Convey realistic expectations of time and commitment needed to be successful.

6. Maintain the HACCP Plan.

6.1. Establish a staff training program.

6.1.1. Recognize the factors that significantly impact employee job performance.

6.1.2. Assess staff training needs using task analysis/SOPs.

The HACCP Training Resource Pack

Location of Materia] in Pack

Module 8

Module 8

Module 3 and Module 7

Module 3

xxxviii Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

Training Objective

6.1.3. Develop written behavioral objectives for SOPs that affect employees' specific work responsibilities.

6.1.4. Integrate RACCP Plans into specific employee work responsibilities.

6.1.5. Evaluate a variety of techniques and methods for deliver­ing training to a diverse work force.

6.1.6. Evaluate the effectiveness of training programs by using objective and performance measurements.

6.2. Establish HACCP Plan maintenance and measurement proce­dures.

6.2.1. Recognize that HACCP systems are dynamic and subject to change/updating.

6.2.2. Identify change factors that significantly affect HACCP Plans and require review of the system.

6.2.3. Recognize support systems and measures for HACCP Plans (management food safety objectives).

6.2.4. Evaluate the appropriateness of different measurement tools that are operation/process specific for HACCP sys­tems.

7. Recognize regulatory issues affecting the implementation of HACCP systems.

7.1. Recognize that the establishment is responsible for producing a safe product and having/implementing a HACCP Plan.

7.2. Identify what assistance is available from the Food Safety Inspection Service (FSIS)/Food and Drug Administration (FDA) or other regulatory agencies.

7.3. Identify and recognize all regulatory requirements:

7.3.1. Sanitation SOPs

7.3.2 Microbiological testing as a verification tool

7.4. Discuss how FSIS/FDA or other regulatory agencies will verify that the RACCP Plan is working satisfactorily.

7.5. Describe enforcement actions for noncompliance.

8. Establish a working RACCP Plan· for the attendees.

The HACCP Training Resource Pack

Location of Material in Pack

Module 8

Module 2

Module 6

. Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. XXXIX

MEETING THE REQUIREMENTS OF THE UK TRAINING STANDARDS (PUBLISHED BY THE RIPHH)

The introductory and advanced-level HACCP Training Standards were produced by a group of HACCP experts known as the HACCP Training Standards Steering Group, assisted and administered by the Royal Institute of Public Health and Hygiene (RIPHH), including members from industry, government, and training organizations.

The training standards consist of a number of training objectives and include core aspects to be covered in HACCP courses and guidance to trainers. Courses are designed to meet the requirements of the training standards and are submitted for approval (to the RIPHH). Approved courses can offer the examining tests produced by the RIPHH.

The following demonstrates where material can be found in the training resource pack that meets the requirements of the training standards. Trainers must review the individual training standards and select appropriate modules or topics for their planned training programs.

Introductory-Level HACCP Training Standard

Location of Training Objective Materia] in Pack

1. Justify the need for a HACCP system. Module 1 and Module 2

2. Show how the legal obligations of food business pro- Module 2 prietors to analyze food hazards and identify critical steps in the business activities should be met in their appropriate industries.

3. List and explain the importance of the principles of Module 1; Module 6; video HACCP.

4. Describe the method by which hazard analysis may Modules 3,4 and 6; video be carried out and appropriate control measures ascer-tained to assess the practical problems.

5. Identify critical control points, including critical limits Module 6; video to ensure their control.

6. Develop suitable monitoring procedures for critical Module 6; video points, and explain the importance of corrective action procedures.

7. Verify the HACCP system by the use of appropriate Module 8 measures.

8. Carry out the steps to introduce and manage a fully operational HACCP system.

The HACCP Training Resource Pack

Modules 3, 7, and 8

xl Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers. Inc.

Advanced Training Standard

Location of Training Objective Materia] in Pack

1. Demonstrate an up-to-date general knowledge of HACCP. Module 1; video

2. Explain how a HACCP system supports national and Modules 2 and 9 international standards, trade, and legislative require-ments.

3. Describe the nature of prerequisite programs and their Module 3 relationship with HACCP.

4. Demonstrate the ability to plan an effective HACCP Module 3 system.

5. Demonstrate a knowledge of how to lead a HACCP Team. Modules 3 and 6; video

6. Demonstrate an understanding of the practical applica- Modules 4,5, and 6 tion of HACCP principles.

7. Demonstrate the ability to design, implement, and Module 8 manage appropriate programs for verification and mainte-nance of HACCP systems.

8. Explain the methods to be used for the effective imple- Module 7 mentation of HACCP.

The advanced level covers a number of topics in much greater depth and introduces some areas not required in the introductory level, such as prerequisites and planning. It is intended for use with courses of 4 to 5 days' duration.

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xli

ADDITIONAL TRAINING OBJECTIVES OF THE HACCP TRAINING RESOURCE PACK

The pack is intended as a flexible resource for trainers to meet all their HACCP training needs. It contains material that goes beyond the requirements of IHA and RIPHH standards.

Additional training objectives covered include the following:

Location of Training Objective Material in Pack

1. Demonstrate an understanding of the training and Module 3 knowledge requirements for HACCP Team members and the work force as a whole.

2. Demonstrate an understanding of the intrinsic factors Module 5 governing the safety of product formulations and methods that can be used to assess safety of new products.

3. Understand the general principles of HACCP and how Video; Modules 1 and 6 they relate to the food handler's role.

4. Develop appropriate training programs for critical Module 7 control point (CCP) monitoring personnel.

5. Demonstrate an understanding of the links between Module 9 HACCP and other quality management techniques and how HACCP may be used as part of a combined product management system.

xlii The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc.

Procedures for Registration of Examination Centers and

Instructors in HACCP

International HACCP Alliance (United States)

For up-to-date information, contact the IHA at the following address:

International HACCP Alliance 120 Rosenthal College Station, TX 77843-2259 Tel: (001) 409 862 3643 Fax: (001) 409 862 3075 Web site: www.haccpalliance.org

Royal Institute of Public Health and Hygiene (UK)

To apply for an up-to-date copy of the HACCP Training Standards (Introductory and Advanced) and syllabus, trainer registration, and examination papers, contact the Exam­inations Department at the following address:

Royal Institute of Public Health and Hygiene 28 Portland Place London WiN 4DE Tel: +44 (0) 20 75802731 or +44 (0) 20 7636 1208 Fax: +44 (0) 20 7580 6157 E-mail: info®riphh.org. uk. Web site: www.riphh.org.uk

The HACCP Training Resource Pack Copyright © 2001 Sara Mortimore & Carol Wallace I Published by Aspen Publishers, Inc. xliii