Current Good Manufacturing Practices (cGMPs) provide the necessary environmental and operating conditions for the production of high quality and safe foods. They are also the building blocks for GFSI-recognized food safety and quality standards, including SQF, BRC, FSSC 22000, and other global standard schemes.
This webinar on cGMPs for GFSI was co-hosted with founder and partner of Food Industry Consulting, Sonia Akbarzadeh, on October 7 at 10:00am MDT.
Sonia covers cGMP basics and how you can use them as building blocks for GFSI compliance.
Specifically, you hear more about:
-Setting up detailed programs and procedures – the 4 stages of cGMPs
-Controlling hazards introduced by personnel, environment, and operations
-Common prerequisite programs
-Elevating the importance of cGMPs as a path to reach GFSI compliance
4. Introduction to GMPs
GMPs
Root of any food safety system
Continuous evolving
GFSI
FSSC 22000, BRC, IFS, SQF, Global Gap
FDA food safety modernization Act (FSMA)
6. Introduction to GMPs
Schemes vary in:
Scope
Structure
Standards
Certification process
Popularity
Schemes have in common
Comprehensive GMPs & HACCP
7. Introduction to GMPs
GMPs
Foundation of HACCP
Detailed programs & procedures
Control hazards introduced by:
personnel, environment & operations
Regulatory requirements countries
products are made & sold in
8. Introduction to GMPs
4 Stages for Successful GMP Programs:
1. Development - write down what you do
Risk assessment
2. Implementation - employee training; provide
recourses/tools/equipment
3. Validation - Initial, annually, for changes
4. Verification - ensure effectiveness
10. Introduction to GMPs
Environmental hazards
Leaking roof
Dirty or corroded equipment
Non-potable water
Pests
Poor ventilation
Damaged packaging
Ingredients received in poor condition
11. Introduction to GMPs
Documentation & Recordkeeping
Controlled documents
Document register to include:
oDocument numbers
oLatest version
oIssued date
oApprover
oLocation (folder & plant)
12. Introduction to GMPs
Documentation & Recordkeeping
Managing document change
Reason for change
Approval of the new version
Old folder
Replacing the plant documents
13. Introduction to GMPs
Documentation & Recordkeeping
Detailed procedures
Verifying records
Recordkeeping
Applicable standards
Customer requirements
Shelf life plus additional one year
14. Introduction to GMPs
Personnel Practices
Each employee
Visitor
Contractor
Training Frequency:
Once they are hired
Annually as refresher
When guidelines are changed
15. Introduction to GMPs
Personnel Practices Verification
Observations
Inspections on a regular basis
Various shifts
Monthly GMP
Internal audit
19. Introduction to GMPs
Master Sanitation Schedule
To include all the items such as:
Overhead & ceilings
Walls
Various equipment
Areas
Racks
Ladders
Catwalks & stairs
Lift trucks
20. Introduction to GMPs
Sanitation program
Validation frequency:
At the design stage
Annually
When any elements changed
Verification:
Prior to production
21. Introduction to GMPs
Water Potability
Adequate
From known clean source
Used as:
Processing aid
Cleaning
Ingredient
Ice
22. Introduction to GMPs
Water Potability
Water testing frequency:
Minimum annually
When changes in:
Source
Delivery system
24. Introduction to GMPs
Water map to indicate:
Water distribution flows
Water holding tank
Water treatment location
Water recycle if applicable
Water sampling points
oTreatment validation
oColor coding non-potable water pipes
25. Introduction to GMPs
Pest Control Program
Methods used to control pests
Assigning responsibility
List of pesticides & chemicals-
Target pest for each pesticide application
Pest elimination method
Frequency of inspection.
Pest control site map
26. Introduction to GMPs
Pest Control Verification:
Service report for completeness &
compliance
Observing the pest Control Operator
Monthly GMP audits
Daily inspection
Pest control company quality assurance
27. Introduction to GMPs
Pest Control Validation
By reviewing:
Annual trend report
Customer complaints
Incidents
Monthly GMP
Audits
28. Introduction to GMPs
Facility and building design
Construction
Location
Plant surroundings
Prevent contamination
29. Introduction to GMPs
Facility & building design
Approved materials by the local regulation
Regular inspection
Elimination of possible contaminations
Flow of waste water (Darin map)
Inspection of the exterior
30. Introduction to GMPs
Equipment and Preventive maintenance
Reduce frequency of regular maintenance
Reduce emergency repairs
Prolonging equipment lifespan
Reduce downtimes
Save time
Save money
32. Introduction to GMPs
New equipment
Meets the desired function
Is easy to clean & maintain
Can be positioned for ease of cleaning &
operation
Its type & design suitable for food production
36. Introduction to GMPs
Receiving/Storage/Shipping
Truck inspection prior to downloading & loading
Product condition inspection
Checklists
List of approved suppliers
Criteria for rejecting incoming materials
Trailer breakdown procedure
Monitoring temperature if applicable
Product & ingredient identification & color
code
Validation of transportation temperature
37. Introduction to GMPs
Allergen Control
Identification
Management
Communication
Comply with regulation where products made &
sold
Such as:
Maximum residue limits, food safety, trade weight,
packaging, product description, nutrition, additives,
allergen labeling, relevant industry codes of practice
38. Introduction to GMPs
Effective allergen program include:
Prevention method
Identifying ingredients & products
Identifying area and equipment
Dedicated storage area
Dedicated utensils & color code
Change over cleaning procedure
Cleaning verification method
Logic production schedule
Reviewing labels
39. Introduction to GMPs
Recall
Lot coding raw materials & products
Minimizing risk to consumers’ health
Fast & efficient procedures
Regain control of unsafe products
Mock recall
40. Introduction to GMPs
Effective recall program
Recall team
Recall coordinator
Recall contact list to include:
o Team 24/7
o Regulatory authorities
o Standard owner
o Certification body
o Customers, distributers, suppliers
o Laboratory, consultants & legal
representative
41. Introduction to GMPs
Effective recall program
Recall forms
Mock recall
Report to include:
Team member name
Duties
Time spent to finish task
Areas of opportunities
Action plan
42. Introduction to GMPs
Training
GMPs
Specific training
Training register:
Participant name
Skills description
Description of the training provided
Date of training completion
Trainer or training provider
Supervisor’s verification
43. Introduction to GMPs
Training sign log to include:
Subject of the trainings
Material used
Participant names
Signatures
Date
Trainer name
Duration of the training