GOOD MANUFACTURING PRACTICES (GMP)/HACCP

Dr.Mohammad Ashraf Paul LPT,FVSC &AH,SKUAST-Kashmir

OBJECTIVE
Guarantee high quality products to the consumer.

Delivering products free of all possible contamination

What are GMPs about?

GMP/GHP All practices regarding the conditions and measures necessary to ensure the safety and suitability of food at all stages of the food chain

GMP
CLOTHING

DRUGS & MEDICATIONS WASTE GLASS & LIGHT FIXTURES PEST CONTROL BINS

TOOLS & MATERIALS

HAIR PROTECTION

CONTRACTORS
PRODUCT PROTECTION FOOD INSERTS

CIGARETTES
PERSONAL HYGIENE FOOD & BEVERAGES

METALS PROTECTION

CLOTHING

CLOTHING

NO JEWELRY ALLOWED IN AREAS OF PRODUCT PRODUCTION OR STORAGE.

Rings / Necklaces / Bracelets / Earrings

Hair clips / Watches

Glasses with jewel decorations

NO OBJECTS CAN BE CARRIED IN POCKETS ABOVE THE WAIST LINE.

CLOTHING

NO SHORTS/ SHORT SLEEVES SHIRTS/ SANDALS ARE ALLOWED IN AREAS OF PRODUCT PRODUCTION OR STORAGE. THE APPROPRIATE UNIFORM OR LAB COAT SHOULD BE WORN IN AREAS OF PRODUCT PRODUCTION OR STORAGE.

HAIR PROTECTION

HAIR PROTECTION

HAIR PROTECTION SHOULD BE WORN IN

AREAS OF PRODUCT PRODUCTION OR STORAGE.

HAIR NETS PROVIDE ADEQUATE HAIR

PROTECTION.
HAIR NETS should cover all the hair.

HAIR PROTECTION

SIDE BURNS that extend beyond ear lobes line

need to be covered by a BEARD NET. need to be covered by a BEARD NET.

MOUSTACHES that extend beyond the mouth line

CIGARETTES

FOOD AND BEVERAGES

FOOD & BEVERAGES

It is FORBIDDEN TO TAKE FOOD or CONSUME

FOOD IN AREAS OF PRODUCT PRODUCTION OR STORAGE. This includes CHEWING GUM.

DRUGS & MEDICATIONS

DRUGS & MEDICATIONS

MEDICATIONS AND PRESCRIBES DRUGS

ARE NOT ALLOWED IN AREAS OF PRODUCT PRODUCTION OR STORAGE.

DRUGS & MEDICATIONS

BANDAGES ALL CUTS should be covered with appropriate

bandages
Clean gloves will be worn to isolate bandages from

products.

GLASS & ILLUMINATION

GLASS & ILLUMINATION

ALL GLASS MATERIALS ARE FORBIDDEN IN

AREAS OF PRODUCT PRODUCTION OR STORAGE.

GLASS & ILLUMINATION

All burnt light bulbs will NOT be discarded in

waste bins in AREAS OF PRODUCT PRODUCTION OR STORAGE.

PEST CONTROL

PEST CONTROL

WHAT ARE THE USUAL PESTS?

INSECTS

MICE/RATS
SPIDERS BIRDS

PEST CONTROL

HOW DO WE CONTROL PESTS?

Maintaining GOOD CONDITIONS OF

SANITATION.
PEST CONTROL PROGRAM.

GMP/ GHP
Primary production Establishment design & facilites location, premises & rooms, equipment, facilities Control of operations Establishment: maintenance & sanitation maintenance & cleaning, pest control, waste management Personal Hygiene health status, illnesses, personal cleanliness, behaviour, visitors Transportation design, use & maintenance Product information & consumer awareness identification, prod info, labelling, consumer education Training

 GMP Manufacture & process controls & includes:

Supplier control Specifications Calibration of equipment Traceability & recall Equipment designs where conditions for food safety can be achieved, maintained & monitored Lighting & ventilation systems Storage conditions Control of operations

 GHP System/ measures for maintaining hygiene & sanitation & include :

Personal hygiene Employee health conditions Maintenance of plant & equipment hygiene including food contact surfaces Pest control Waste disposal, Water quality Toilet & hand wash facilities Prevention of cross contamination

HACCP
Raw and end-products may be tested for the presence, level, or absence of microorganisms. Traditionally these practices were used to reduce manufacturing defects in dairy products and ensure compliance with specifications and regulations, however, they have following drawbacks:

Drawbacks of traditional practices: 1. Destructive and time consuming 2. Slow response 3. Small sample size 4. Delays in the release of food

In 1960s the Pillsbury company, the U.S. Army, and NASA introduced a system for assuring pathogen free foods for the space programme. This system, called Hazard Analysis and Critical Control Points (HACCP), is a focus on critical food safety areas as part of TQM . Involves a critical examination of entire food manufacturing process to determine every step where there is a possibility of physical, chemical, or microbiological contamination which would render food unsafe or unacceptable for human consumption .

 An internationally accepted methodology to reduce and manage risk A preventive system for food safety that addresses chemical, physical and biological risk Treats the production of food as a total, continuous system, assuring food safety from harvest to consumption 7 Principles & 12 Steps

Seven principles to HACCP: 1. 2. 3. 4. 5. 6. 7. Analyze hazards Determine CCPs Establish critical limits Establish monitoring procedures Establish deviation procedures Establish verification procedures Establish record keeping procedures.

HACCP 12 Steps Assemble HACCP Team Describe Product Identify intended Use Pre -Steps Construct Flow Diagram Onsite Confirmation of Flow Diagram List all potential hazards associated with each step, conduct a hazard analysis & consider any measures to control identified hazards Determine the CCPs Establish Critical Limits for each CCP Establish a monitoring system for each CCP Establish Corrective Actions to deviations Establish Verification Procedures Establish documentation & Record Keeping

Terms and definitions

Food Safety - concept that food will not cause harm to the consumer when it is prepared and/or eaten according to its intended use Food chain - sequence of the stages and operations involved in the production, processing, distribution, storage and handling of a food and its ingredients, from primary production to consumption

Food safety hazard - biological, chemical or physical agent in food, or condition of food, with the potential to cause an adverse health effect
Food safety policy - overall intentions and direction of an organization related to food safety as formally expressed by top management End product - product that will undergo no further processing or transformation by the organization

Terms and definitions

Critical control point CCP - at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level Critical limit - criterion which separates acceptability from unacceptability Monitoring - conducting a planned sequence of observations or measurements to assess whether control measures are operating as intended Correction - action to eliminate a detected nonconformity Corrective action - action to eliminate the cause of a detected nonconformity or other undesirable situation

Terms and definitions

Validation - obtaining evidence that the control measures managed by the HACCP plan and by the operational PRPs are capable of being effective Verification - confirmation, through the provision of objective evidence, that specified requirements have been fulfilled Updating - immediate and/or planned activity to ensure application of the most recent information

Example of processing for safety

RAW MATERIAL

Milk

Potential hazards

Salmonella Campylobacter

Control measure

Heating

Critical Control Point

Boiling in pan

Monitoring

Observation of foaming

Verification

Observation of foam residues

Use

Drinking while still hot

( This prevents recontamination and growth which may lead to hazards )