PARINOS- Q CHECK CERTIFICATION.pdf

The role of certification bodies in auditing Prerequisite programmes in the food industry

sector, according to ISO 22000 / TS 22002-1:2009 (Prerequisite programmes on food

safety — Part 1: Food manufacturing).

New consumer trends, certifications and industry internal auditing protocols deriving

from Nutrition, Genetically modified food, allergens labeling and food defense issues

Konstantinos Parinos

Lead Auditor Q-Check

Veterinarian, DVM, Chemist , Μ.Sc.

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ISO / TS 22002-1:2009

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ISO / TS 22002-1:2009

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ISO / TS 22002-1:2009

ISO 22000:2005 sets out specific food safety requirements for organizations in the food

chain.

One such requirement is that organizations

establish, implement and maintain prerequisite programmes (PRP) to assist in controlling food

safety hazards (ISO 22000:2005, Clause 7).

ISO / TS 22002-1:2009

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Auditing ISO / TS 22002-1:2009

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EFSIS

Nestlé NQS

FAMI-QS

GMO

ISO 9001

GMP standard for Corrugated & Solid Board

IFS

GFSIGuide

SQF

AG 9000

ISO 14001

McDonalds system

Kraft food system

Eurepgap

Friesland Coberco FSS

DS 3027

BRC-IoP

BRC-Food

Dutch HACCP

Irish HACCP

M&S system

Aldi system

Waiterosesystem

GMP GTP

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CAC/RCP Codex Alimentarius Commission/ Recommended International Code of Practice

ISO International Organization for Standardization

ANSI American National Standards Institute

GFSI Global Food Safety Initiative

IFC International Food Standard

GMP/GRP Good Manufacturing/Retail Practice

FSMS Food Safety Management System

BRC British Retail Consortium

SQFI Safe Quality Foods Institute

GMA-Safe Supplier Assessments For Food Excellence Grocery Manufacturers Association (2001)

Audit System Terms and Acronyms

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This Technical Specification is intended to be used to supportmanagement systems designed to meet the requirements

specified in ISO 22000:2005, and sets out the detailedrequirements for those programmes.

This Technical Specification does not duplicate requirements

given in ISO 22000:2005 and is intended to be used inconjunction with ISO 22000:2005.

ISO / TS 22002-1:2009

ISO 22000 TS 22002-1

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Food manufacturing operations are diverse in nature and notall of the requirements specified in this Technical

Specification apply to an individual establishment orprocess.

Role of the auditor and the certification body.

This Technical Specification is applicable to allorganizations, regardless of size or complexity, which are

involved in the manufacturing step of the food chain and wish

to implement PRP in such a way as to address the

requirements specified in ISO 22000:2005, Clause 7.

ISO / TS 22002-1:2009

ISO 22000 TS 22002-1

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ISO / TS 22002-1:2009)

ISO 22000 TS 22002-1

BS PAS 220: 2008

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Prerequisite programmes

When selecting and/or establishing PRP´s documents to be

considered are:

a) Regulatory and consumer requirements

b) Information from industry guidelines

c) Specific product requirements for foods to be produced

d) Any additional points linked to local environment

ISO 22000 TS 22002-1

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ISO / TS 22002-1:2009

Prerequisite programmes

ISO 22000 TS 22002-1

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This Technical Specification specifies detailed requirements to

be specifically considered in relation to ISO 22000:2005,

7.2.3:

a) construction and layout of buildings and associated utilities;

b) layout of premises, including workspace and employee

facilities;

c) supplies of air, water, energy and other utilities;

d) supporting services, including waste and sewage disposal;

e) suitability of equipment and its accessibility for cleaning,

maintenance and preventive maintenance;

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f) management of purchased materials;

g) measures for the prevention of cross-contamination;

h) cleaning and sanitizing;

i) pest control;

j) personnel hygiene.

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In addition, this Technical Specification adds other aspects

which are considered relevant to manufacturing operations:

1) rework;

2) product recall procedures;

3) warehousing;

4) product information and consumer awareness;

5) food defence, biovigilance and bioterrorism.

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DESIGN

Buildings, Internal layout

Movement patterns

Openings

Walls, floors, drains, ceilings and overhead fixtures

Equipment

Laboratory

Storage areas

Distribution of utilities

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Locations of establishments

The site boundaries shall be clearly identified.

Access to the site shall be controlled.

The site shall be maintained in good order.

Vegetation shall be tended or removed.

Roads, yards and parking areas

shall be drained to prevent

standing water and shall be

maintained.

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The building shall provide adequate space, with a logicalflow of materials, products and personnel, and physical

separation of raw from processed areas.

Location of equipment. Equipment shall be designed and

located so as to facilitate good hygiene practices and

monitoring. Equipment shall be located to permit access for

operation, cleaning and maintenance.

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Internal structures and fittings

Process area walls and floors shall be washable or cleanable,

as appropriate for the process or product hazard. Materials of

construction shall be resistant to the cleaning system applied.

Wall floor junctions and corners shall be designed to facilitate

cleaning.

It is recommended that wall floor

junctions be rounded in processing areas.

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Floors shall be designed to avoid standing water.

In wet process areas, floors shall be sealed and drained.

Drains shall be trapped and covered.

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Storage areas shall be designed or arranged to allow

segregation of raw materials, work in progress and finished

products.

External opening windows, roof vents or fan, where present,

shall be insect screened.

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aaaa Cert Ευρωπαϊκός Οργανισµός Πιστοποίησης Α.Ε.

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Ceilings and overhead fixtures shall be designed to

minimize build-up of dirt and condensation.

Lighting The lighting provided (natural or artificial) shall allow

personnel to operate in a hygienic manner. The intensity of the

lighting should be appropriate to the nature of the operation.

Light fixtures shall be protected to ensure that materials,

product or equipment are not contaminated in the case of

breakages.

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Openings intended for transfer of materials shall be designed

to minimize entry of foreign matter and pests.

External opening doors shall be closed or screened when

not in use.

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In-line and on-line test facilities shall be controlled to

minimize risk of product contamination.

Microbiology laboratories shall be designed, located and

operated so as to prevent contamination of people, plant and

products.

They shall not open directly on to a production area.

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Temporary structures shall be designed, located and

constructed to avoid pest harbourage and potential

contamination of products.

Additional hazards associated with temporary structures and

vending machines shall be assessed and controlled.

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Facilities used to store ingredients, packaging and products

shall provide protection from dust, condensation, drains, waste

and other sources of contamination.

Storage areas shall be dry and well ventilated. Monitoring

and control of temperature and humidity shall be applied

where specified.

.

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• All materials and products shall be stored off the floor and

with sufficient space between the material and the wallsto allow inspection and pest control activities to be carried

out.

The storage area shall be designed to allow maintenance and

cleaning, prevent contamination and minimize deterioration.

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• A separate, secure (locked or otherwise access controlled)

storage area shall be provided for cleaning materials,

chemicals and other hazardous substances.

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UTILITIES – AIR, WATER, ENERGY

Sufficient supply of potable water

Boiler chemical approved

Established requirements for filtration, humidity andmicrobiological specifications for air used as aningredient or in direct contact with food

Compressed air

Adequate lighting to enable operation in a hygienicmanner

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Water supply

The supply of potable water shall be sufficient to meet the

needs of the production process(es).

• Facilities for storage, distribution and, where needed,

temperature control of the water shall be designed to meet

specified water quality requirements.

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Water used as a product ingredient, including ice or steam

(including culinary steam), or in contact with products or

product surfaces, shall meet specified quality and

microbiological requirements relevant to the product.

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Water for cleaning or applications where there is a risk of

indirect product contact (e.g. jacketed vessels, heat

exchangers) shall meet specified quality and microbiological

requirements relevant to the application.

Where water supplies are chlorinated, checks shall ensure

that the residual chlorine level at the point of use remains

within limits given in relevant specifications.

Non-potable water shall have a separate supply system that

is labelled and not connected to the potable water system.

Take measures to prevent non-potable water refluxing into the

potable system.

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Boiler chemicals, if used, shall be either:

a) approved food additives which meet relevant additive

specifications; or

b) additives which have been approved by the relevant

regulatory authority as safe for use in water intended for

human consumption.

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Boiler chemicals shall be stored in a separate, secure(locked or otherwise access-controlled) area when not in

immediate use.

• Where oil is used for compressors and there is potential for

the air to come into contact with the product, the oil used

shall be food grade.

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The organization shall establish requirements for filtration,humidity (RH%) and microbiology of air used as an

ingredient or for direct product contact.

Where temperature and/or humidity are deemed critical by

the organization, a control system shall be put in place and

monitored.

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Ventilation (natural or mechanical) shall be provided to

remove excess or unwanted steam, dust and odours, and to

facilitate drying after wet cleaning

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• Room air supply quality shall be controlled to minimize risk

from airborne microbiological contamination.

Protocols for air quality monitoring and control shall be

established in areas where products which support the growth

or survival of microorganisms are exposed.

Ventilation systems shall be designed and constructed such

that air does not flow from contaminated or raw areas to clean

areas. Filters supplying air with direct product contact and

potential to introduce pathogens must be regularly monitored

and replaced when necessary.

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Specified air pressure differentials shall be maintained.

Systems shall be accessible for cleaning, filter changing and

maintenance. Exterior air intake ports shall be examined

periodically for physical integrity.

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Compressed air, carbon dioxide, nitrogen and other gassystems used in manufacturing and/or filling shall be

constructed and maintained so as to prevent contamination.

Gases intended for direct or incidental product contact

(including those used for transporting, blowing or drying

materials, products or equipment) shall be from a source

approved for food contact use, filtered to remove dust, oil and

water.

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WASTE DISPOSAL

Identification, collection and disposal of waste materials

Appropriate containers for waste

Segregation and storage of waste

Drains and drainage

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Waste disposal

Systems shall be in place to ensure that waste materials areidentified, collected, removed and disposed of in a manner

which prevents contamination of products or production areas.

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Containers for waste and inedible or hazardous substances

shall be: a) clearly identified for their intended purpose;

b) located in a designated area;

c) constructed of impervious material which can be readily

cleaned and sanitized;

d) closed when not in immediate use;

e) locked where the waste may pose a risk to the product.

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Waste management and removal

Provision shall be made for the segregation, storage and

removal of waste. Accumulation of waste shall not be allowed

in food-handling or storage areas. Removal frequencies shall

be managed to avoid accumulations, with a minimum dailyremoval.

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Labelled materials,

products or printed packaging

designated as waste shall be

disfigured or destroyed to ensure that trademarks cannot be reused.

Removal and destruction shall

be carried out by approved

disposal contractors.

The organization shall retain

records of destruction.

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EQUIPMENT SUITABILITY, CLEANING AND MAINTENANCE

Design and construction of food contact equipment

Hygienic design eg. Smooth, accessible, compatible with

intended products

Temperature control and monitoring equipment

Cleaning plant, utensils and equipment

Preventive and corrective maintenance

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Food contact equipment shall be designed and constructed

to facilitate cleaning, disinfection and maintenance.

Contact surfaces shall not affect, or be affected by, the

intended product or cleaning system. Food contact equipment

shall be constructed of durable materials able to resist

repeated cleaning.

Hygienic design Equipment shall be able to meet established

principles of hygienic design, including:

a) smooth, accessible, cleanable surfaces, self draining in wet

process areas;

b) use of materials compatible with intended products and

cleaning or flushing agents;

c) framework not penetrated by holes or nuts and bolts.

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ISO / TS 22002-1:2009

Temperature control and monitoring equipment

Equipment used for thermal processes shall be able to meet

the temperature gradient and holding conditions given in

relevant product specifications.

Equipment shall provide for the monitoring and control of the

temperature..

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ISO / TS 22002-1:2009

Cleaning plant, utensils and equipment. Wet and dry

cleaning programmes shall be documented to ensure that all

plant, utensils and equipment are cleaned at defined

frequencies. The programmes shall specify what is to be

cleaned (including drains), the responsibility, the method of

cleaning (e.g. CIP, COP), the use of dedicated cleaning tools,

removal or disassembly requirements and methods for verifying the effectiveness of the cleaning. .

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ISO / TS 22002-1:2009

Preventive and corrective maintenance

A preventive maintenance programme shall be in place.

The preventive maintenance programme shall include all

devices used to monitor and/or control food safety hazards.

Corrective maintenance shall be carried out in such a way that

production on adjoining lines or equipment is not at risk of

contamination.

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ISO / TS 22002-1:2009

Management of purchased materials

Selection and management of suppliers

Incoming material requirements

Inspection of incoming material

Nonconforming received materials

Identification, segregation and handling of purchased materials

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ISO / TS 22002-1:2009

MEASURES FOR PREVENTION OF CROSS CONTAMINATION

Microbiological cross contamination

Allergen management

Physical contamination

Chemical contamination

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ISO / TS 22002-1:2009

CLEANING AND SANITIZING

Cleaning and sanitizing agents and tools

Cleaning and sanitizing programmes

Cleaning in place (CIP) systems

Monitoring sanitation effectiveness

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ISO / TS 22002-1:2009

PEST CONTROL

Pest control programmes

Preventing access

Harborage and infestations

Monitoring and detection

Eradication

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ISO / TS 22002-1:2009

PERSONNEL HYGIENE AND EMPLOYESS FACILITIES

Adequate numbers, locations and means of hygienically

washing and drying

Adequate number of toilets

Not directly open into production

Changing facilities for personnel

Canteens and designated areas for food storage

Work wear and protective clothing

Health status

Illness and injuries

Personal cleanliness

Personal behavior

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ISO / TS 22002-1:2009

REWORK

Storage, identification and traceability

Segregation requirements for rework

Classification for rework

Rework usage – permissible incorporation

PRODUCT RECALL PROCEDURES

Recall requirements

System for identification, location and removal

Need for public warning

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ISO / TS 22002-1:2009

WAREHOUSING

Effective control of warehousing temperature, humidity and

environmental conditions

Proper stacking

Waste materials, lubricants, chemicals, cleaning materials and

pesticides stored separately

Vehicles, conveyances and containers

PRODUCT INFORMATION / CONSUMER AWARENESS

Proper presentation

Labeling of pre-packed food

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Industry supplier requirements: NutritionGenetically modified food, allergens labeling

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Nutrition information on processed foodsIf they choose to provide nutrition information it must be in

one of two formats

Front-of-pack labelling

• Traffic light labels on the front-of-packprovides information on high (red), medium (amber) or low (green) amounts of fat, saturated fat, sugars and salt.• The number of grams of fat, saturated fat, sugars and salt in what the manufacturer or retailer suggests as a ‘serving’ of the food though the criteria are per 100g

Format 2: ‘Big 4 and Little 4’Energy (kJ and kcal)Protein (g)Carbohydrate (g)of which: sugars (g)Fat (g)of which: saturates (g)Fibre (g)Sodium (g)

Format 1: ‘Big 4’Energy (kJ and kcal)Protein (g)Carbohydrate (g)Fat (g)

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Guideline Daily Amount (GDA)Guideline Daily Amounts (GDAs) are guidelines for healthy

adults and children on the approximate amount of calories,

fat, saturated fat, carbohydrate, total sugars, protein, fibre, salt

and sodium required for a healthy diet

GDAs are not targets for individuals to consume, but a

guideline or benchmark to help them make dietary choices

and balance their daily intake

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How do consumers react to nutrition labels? Conclusions from research in Europe

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New consumer trends

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Front of pack labelling evaluation research

• Research is to evaluate the impact of the various FOP nutritional signposting schemes on consumer knowledge and behaviour

• The coexistence of a range of FOP label formats causes difficulty for shoppers

• The strongest labels are those which include all of:

- Words ‘High/med/low’ +

- Traffic lights +

- %Guideline Daily Amount

BUT

• European Parliament failed to adopt traffic light labeling (June 2010)

• Quantities per 100g, GDAs and country of origin labeling

were approved

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Retailers & labelling systems

Different retailers and nutrition labelling systems.

Retailers Labelling systems

UK TescoSainsbury’sAsda

GDAColour coded traffic light (TL) levelsTL with GDA

France IntermarchéAuchan

Colour coded levels (not TL) and GDA, BOP GDA

Germany LidlReal

GDAGDA (energy only FOP)

Hungary Tesco, Interspar GDA

Poland Tesco, Real GDA

Sweden ICA, Coop, Axfood Health logo (keyhole) + GDA

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New consumer trends Widespread interest in nutrition information

Consumers like the idea of simplified front of pack information

But differ in their ‘liking’ of different formats

Most consumers believe they understand the most common

graphic formats. Very little insight into how labelling

information is/will be used in real life.

85% average penetration of BOP nutrition information of any kind

48% average penetration of FOP nutrition information of any kind

BOP FOP

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New consumer trends Did you look for any nutrition information on the packaging?

Less than 27% said they looked for nutrition information

� These figures are supported by respective respondents being able to

� name at least one nutrient and

� show where on the pack that info is found

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Industry supplier requirements: Genetically modified food

Q-Check 77Europe requires that all food that has any ingredient that is

more than 1% GM be labeled as “GM containing”.

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Industry supplier requirements: Genetically modified food

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Κ.Ν.Parinos

Auditing ISO / TS 22002-1:2009What Is Food Defense?

FOOD DEFENCE, BIOVIGILANCE AND TERROISIM

Assessment of hazards to products posed by potential acts of

sabotage, vandalism or terrorism. Access controls.

Food defense is not food safety. Food safety addresses

predictable and unintentional risks. Food safety is best

addressed through HACCP.

Food defense addresses intentional attacks on the safety or

quality of food. It is not well suited to HACCP.

Who Would Do This?

Terrorists or Activists, Competitors, Disgruntled employees

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Auditing ISO / TS 22002-1:2009Food Defense?

Why?

Anger over national, business, or personal differences

Seeking changes in culture, Seeking economic disruption

Seeking public fear, Seeking harm to others

Factors that increase risk:

Making large batches of food

Foods with short shelf lives

Uniformly mixed products

Products that reach key populations, Ease of access

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Αreas important

Management

Outside Security

Inside Security

Slaughter/Processing

Storage

Shipping/Receiving

Water, Ice, Ingredients

Mail

PersonnelQ-Check 81

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Areas to Consider: Food Defense Management.

Do you have a food defense plan?

Is someone responsible?

Do you have related necessary plans, such as product

withdraw or recall and personnel emergency or evacuation

procedures?

Do you keep doors closed?

Do you have a fence?

Is there adequate lighting?

Do you control access by people and vehicles?

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Areas to Consider: Inside Defense Measures

Do you use surveillance?

Do you have alert systems?

Do you control access?

Do you take inventory?

Areas to Consider: Slaughter/Processing Measures

Are animals or batches or product exposed to tampering?

Are areas or equipment left unobserved?

Will employees report unusual situations?

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Areas to Consider: Storage

Is access limited?

Is inventory maintained?

Can the impact of an attack be minimized?

Areas to Consider: Shipping and Receiving T

Are trailers sealed?

Are drivers identified and deliveries scheduled?

Are all vendors selected thoughtfully?

Are returned goods examined closely?

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Areas to Consider: Water, Ice, and Ingredients.

Are water lines secure?

Is ice-making equipment protected?

Are all bulk ingredients protected when not in use?

Areas to Consider: Mail

Is mail opened away from other areas?

Are procedures understood for handling suspect mail

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Areas to Consider: Personnel

Are background checks completed?

Are personnel supervised?

Are employees trained?

Are lockers inspected?

Are cameras allowed?

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Auditing ISO / TS 22002-1:2009CARVER Food Defense?

C—Criticality

A—Accessibility

R—Recuperability

V—Vulnerability

E—Effect

R—Recognizability

SHOCK

How deeply would an attack impact people?

Employees/community/nation, Symbolism/history

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Κ.Ν.Παρινός Q-Check 88

The role of certification bodies in auditing Prerequisite programmes in the food industry

sector, according to ISO 22000 / TS 22002-1:2009 (Prerequisite programmes on food

safety — Part 1: Food manufacturing).

New consumer trends, certifications and industry internal auditing protocols deriving

from Nutrition, Genetically modified food, allergens labeling and food defense issues

Konstantinos Parinos

Lead Auditor Q-Check

Veterinarian, DVM, Chemist , Μ.Sc.

Q-Check 89

PARINOS- Q CHECK CERTIFICATION.pdf

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Transcript of PARINOS- Q CHECK CERTIFICATION.pdf