News and Trends of Food Safety Standards

News and Trends of Food Safety Standards Belgrad, September 2012 Alfred Greimel

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Quality Austria: issued certificates 08/12 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 - Folie 2 -

What is GFSI? The Global Food Safety Initiative (GFSI) is a d ivision of the Consum er Good s Forum and a collaboration of retailers, m anufactu rers and food service com p anies that has been w orking on harm onization of food safety stand ard s.

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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

Mag. Elisabeth Voltmer, September 2012

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Food Safety System Certification 22000


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 What was the solution?

Danone, Unilever, Kraft, Nestlé (Big 4) and CIAA Confederation of the European Food und Drink Industry have developed PAS 220 together with BSI

2 Yves Rey GFSI Vice Chair


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2

Yves Rey GFSI Vice Chair


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BASICS ISO 22000 and ISO 22002-1  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. Mag. Elisabeth Voltmer, September 2012

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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 evaluate them in audits!! Mag. Elisabeth Voltmer, September 2012

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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


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BRC – Global Standards


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BRC Version 6


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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.


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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. Mag. Elisabeth Voltmer, September 2012

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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


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Special requirements defined in the standard


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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


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DecisionTree metal detection


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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 Mag. Elisabeth Voltmer, September 2012

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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 Mag. Elisabeth Voltmer, September 2012

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IFS – International Featured Standard FOOD


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IFS 6 – new requirements

Chapter 6:

neu

FOOD DEFENSE

What has to be considered according to IFS Version 6?  Defense Assessment  Site Security  Personnel & Visitor Security  External Inspections Mag. Elisabeth Voltmer, September 2012

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FOOD DEFENSE – what does it mean?  Defense, control…? …protection of food products…  Food Defense  Food Safety same intention simular hazards

 safe food  physical, chemical, microbiological  hazard analysis and assessment of associated risks

method

difference?

Intentional contamination



unintentional contamination


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FOOD DEFENSE  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.

Identification of vulnerabilities


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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 Mag. Elisabeth Voltmer, September 2012 - Folie 26 procedure.

FOOD DEFENSE – practical approach 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,…=? Mag. Elisabeth Voltmer, September 2012

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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?


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FOOD DEFENSE – practical approach Site Security ..

to prevent unauthorized access to services, products and ingredients that could adversely affect the content or safety of food.

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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…

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

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Video cameras and sufficient light

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Personnel is trained in order to be able to identify tampering of raw materials and packaging materials best possible.

Check by

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Site inspections

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Internal and external audits

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Visitor records Mag. Elisabeth Voltmer, September 2012

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FOOD DEFENSE - practical approach 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.

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

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Truck drivers that load or unload products or materials are restricted to defined areas outside the building.

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

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

production areas. Mag. Elisabeth Voltmer, September 2012

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FOOD DEFENSE – practical approach External Inspections … to make sure that only authorized personnel have access to manufacturing and storage areas and sample collection.

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Registration and signing of any kind of external organizations

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

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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.

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Red hairnet also for authorities


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FOOD DEFENSE – practical approach Do not forget also to think about Data Security 

Access to server rooms is only permitted for defined staff members

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Web-security: Firewall, Spam, Virusscan,…

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Pass words with a high security

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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,…) Mag. Elisabeth Voltmer, September 2012

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FOOD DEFENSE – practical approach You will find more information and useful instructions and hints in the IFS Food Defense GUIDELINE


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Thank you very much for your attention!


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