News and Trends of Food Safety Standards

Alfred Greimel - 1 -

News and Trends of Food Safety Standards

Belgrad, September 2012

- Folie 2 -

Food safety system management/ Hygienemanagement:

ISO 22000: (150) 206 (Uruquay, Serbia, Iran, Turkey, Italy)

FSSC: 16, Agrana (international producer of fruit and starch); requests internat Israel, Uruguay, Serbia. Suppliers of Coca Cola

HACCP: (301)/360 plus 16 ISO 15593 (packaging material)

IFS: (170)/188 Zertifikate, 2 IFS Broker

IFS Logistic: (8)/11: alle Spar Logistic Standorte kommen

BRC Global standard food: 61/65, BRC/GS packaging: 18/20;

FACE (spain scheme, free of allergens / gluten): 2

1001 active certificates for the Food Scope ISO 9001: 609; ISO 14000: 92

629 active certificates in food safety schemes (all scopes packaging, Service, inkl.primary production), IFS 149, ISO 22000: 164

Quality Austria: issued certificates 08/12

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../../../../Local%20Settings/Temp/QA_PROFIL_2012_07_E.pdf

www.22000-Tools.com

What is GFSI?

The Global Food Safety

Initiative (GFSI) is a d ivision

of the Consumer Goods

Forum and a collaboration

of retailers, manufacturers

and food service companies

that has been working on

harmonization of food

safety standards.

http://www.22000-Tools.com



Mag. Elisabeth Voltmer, September 2012 - Folie 4 -

GFSI-Recognised Schemes: Sept. 2012

Dutch HACCP

Foundation for Food Safety

Certification (FSSC) focus on the

management of the FSSC 22000

scheme which they also own.

Synergy 22000

agreement between FSSC 22000 and

the management of Synergy 22000



Food Safety System Certification 22000

Mag. Elisabeth Voltmer, September 2012 - Folie 7 - Yves Rey GFSI Vice Chair

Danone, Unilever, Kraft, Nestlé (Big 4) and

CIAA Confederation of the European Food und

Drink Industry have developed PAS 220

together with BSI

What was the solution?

2

Mag. Elisabeth Voltmer, September 2012 - Folie 8 - Yves Rey GFSI Vice Chair

2


ISO 22000:2005 sets out specific food safety requirements for manufacturing organizations in the food chain, regardless of size or complexity.

Characteristic requirement is that organizations have to establish, implement and maintain PRPs which would assist in controlling food safety hazards (ISO 22000:2005, Requirement 7.2).

ISO 22002-1 does not duplicate requirements given in ISO 22000:2005 and is intended to be used in conjuction with ISO 22000:2005. (FSSC 22000)

SETS DETAILED REQUIREMENTS FOR SPECIFIC PRPs

This Technical Specification is neither designed nor intended for use in other parts of food supply chain.

Food manufacturing opeartions are diverse in nature and not all of the requirements specified in this Technical Specification apply to an individual establishment or process.

BASICS ISO 22000 and ISO 22002-1


Actual focus for auditors in SAFETY STANDARDS

Consistent interpretation of high risk and high care areas and expected controls

Validation and verification

Food Defence

Pest control / risk assessment

Allergens / allergen management

Foreign materials / metal detection

Traceability

Food contact materials (FCM) / migration

main focus for auditors: CCP and how to evaluate them in audits!!


What are the main topics in

any auditing process?

good manufacturing practices within the production areas

Supplier management, foreign body control and allergen management

Layout, product flow and segregation

Housekeeping and hygiene

Glass register

Calibration of metal detection test pieces

Post allergen cleaning validation methods


BRC – Global Standards


BRC Version 6


Understanding Production risk zones

A (specific BRC) decision tree and high risk/high care requirements are based on Listeria risks

Listeria has a low infective dose 1,000/g and can multiply at low temperatures

It presents a significant food safety risk

Note also E.Coli 0157 has a very low infective dose.


High Risk:

Chilled/Frozen ready to eat products

Processed to remove Listeria: 70°C for at least 2 minutes (6 log reductions).

but

vulnerable to growth of Listeria

and

not expected to undergo a kill step by the consumer.

The high risk zone only applies where the product is still open – until enclosing in packaging.


High Care:

Chilled or frozen ready to eat products

The production process reduces listeria (typically 2 log reduction) but it does not eliminate this risk completely - therefore Listeria may be present.

These products must be controlled by short shelf life

Products need protecting in order to avoid further contamination


Special requirements defined in the standard


Metal Detection (spec. BRC)

Where customers do not specify metal detection a decision tree may be used

Where the absence of metal detection is accepted this must be justified in the report


Decision- Tree

metal detection


New focus:

Validation und Verification / Guideline: CAC/GL 69 - 2008

Verification: The application of methods, procedures, tests and other evaluations, in addition to monitoring, to determine whether a control measure is or has been operating as intended

Validation: Obtaining evidence that a control measure or combination of control measures, if properly implemented, is capable of controlling the hazard to a specified outcome


Metal Detection / Example

Objective: To identify ad remove the risk of metal contamination in product.

Validation:

Review of rejected materials

Challenging test methods and materials

Challenging sensitivity levels

Customer complaints

Verification:

System detection and rejection tests

Technical system review and preventative maintenance


IFS – International Featured Standard FOOD


IFS 6 – new requirements

Chapter 6: FOOD DEFENSE

neu

What has to be considered according to IFS Version 6? Defense Assessment Site Security Personnel & Visitor Security External Inspections


Defense, control…?

…protection of food products…

Food Defense Food Safety

same intention safe food

simular hazards physical, chemical,

microbiological

method hazard analysis and

assessment of associated risks

difference?

Intentional contamination unintentional contamination

FOOD DEFENSE – what does it mean?


The main focus of FOOD DEFENSE is to protect food and all steps of

production from any kind of intentional adulteration without

discovery.

The hazard analysis and assessment of associated risks should take into

consideration the ability to introduce a contaminant agent at the most

convenience and less controlled stages in the process, packaging, storing,

transportation and warehousing and the likelihood as well as the severity of

occurence.

FOOD DEFENSE

Identification of vulnerabilities


IFS – FOOD DEFENSE CHECKLIST 6. Food defense and external inspections

6.1 Defense assessment

6.1.1 Responsibilities for food defense shall be clearly defined. Those responsible shall be key staff or shall have access to the top management team.

Sufficient knowledge in this area shall be demonstrated.

6.1.2 A food defense hazard analysis and assessment of associated risks shall have been performed and documented. Based on this assessment, and

based on the legal requirements, areas critical to security shall be identified.

Food defense hazard analysis and assessment of associated risks shall be conducted annually or upon changes that affect food integrity.

An appropriate alert system shall be defined and periodically tested for effectiveness.

6.1.3 If legislation makes registration or onsite inspections necessary, evidence shall be provided.

6.2 Site Security

6.2.1 Based on a hazard analysis and assessment of associated risks, identified areas critical to security shall be adequately protected to prevent

unauthorized access.

Access points shall be controlled.

6.2.2 Procedures shall be in place to prevent tampering and/ or allow identification of signs of tampering.

6.3 Personnel & Visitor Security

6.3.1 Visitor policy shall contain aspects of food defense plan. Delivery and loading staff in contact with the product shall be identified and shall respect the

access rules of the company. Visitors and external service providers shall be identified in areas with product storage and shall be registered at the time

of access. They should be informed about the site policies and their access controlled accordingly.

6.3.2 All employees shall be trained in food defense on an annual basis or when significant program changes occur. The training sessions shall be

documented.

Employee hiring and employment termination practices shall consider security aspects as permitted by law.

6.4 External Inspections

6.4.1 A documented procedure shall exist for managing external inspections and regulatory visits. Relevant personnel shall be trained to execute the

procedure.


Defense Assessment

.. in order to identify vulernabilities, the FOOD DEFENSE team should

considered the following aspects:

Exterior

Are doors, windows and roof areas kept secure?

Is there controlled access of people and vehicles?

Are parking areas controlled and adequately protected?

Are there back-up sources of critical utilities such as electrical, water,… in case of emergency?

Are ventilation systems protected in an adequate way?

Interior

Is access of staff limited to appropriate work location, job function and working hours?

Is access controlled in general?

Are surveillance methods used in critical areas (cameras, supervision,…=?

FOOD DEFENSE – practical approach


Defense Assessment

.. in order to identify vulernabilities, the FOOD DEFENSE team in our

company considered the following aspects:

Shipping and Receiving

Are the transportation vessels sealed/locked when necessary (especially bulk tanks)?

Are deliveries scheduled?

Raw materials

Is there any kind of unintentional contamination possible?

Water, ice, steam sources used on site under control?

Packaging materials and product labels up to legal requirements?



Site Security

.. to prevent unauthorized access to services, products and ingredients that could

adversely affect the content or safety of food.

Optimal: physical barrieres (external and internal): critical e.g. laboratories handling

chemicals and reagents, any area where hazardous materials are stored or critical areas

themselves like central water tanks…

Limited access for all staff members (electronic pass keys, alarm systems,..)

Video cameras and sufficient light

Personnel is trained in order to be able to identify tampering of raw materials and

packaging materials best possible.

Check by

Site inspections

Internal and external audits

Visitor records



Personnel and Visitors

…. Limited and controlled access in order to protect against misuse.

Registration of visitors and service providers and signing of internal requirements

before they are permitted on-site.

Food defense trainings for all employees in order to increase sensivity to food defense

aspects.

Truck drivers that load or unload products or materials are restricted to defined areas

outside the building.

Visitors get special hygienic clothes (red hairnet) and escorts are required to guide

them.

It is not allowed to take personal articles of daily life or drugs (medicine) to

production areas.

FOOD DEFENSE - practical approach


External Inspections

… to make sure that only authorized personnel have access to manufacturing

and storage areas and sample collection.

Registration and signing of any kind of external organizations

Special procedure that defines the criteria to follow in case of an external inspection

Levels of authority are defined with respect to the kind of information that is allowed

to be provided.

Sample collection must take place guided by a member of quality assurance

department.

Red hairnet also for authorities



Do not forget also to think about

Data Security

Access to server rooms is only permitted for defined staff members

Web-security: Firewall, Spam, Virusscan,…

Pass words with a high security

Special trainings for employees in order to ensure that

PC are looked after work or during breaks

no secret documents are left next to printers,…

notebooks are stored in a safe area (not in cars,…)



You will find more information and useful instructions

and hints in the

IFS Food Defense GUIDELINE


../../../Desktop/IFS Food Defense guideline_DE 2012_02_03.pdf


Thank you very much for your attention!

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