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

1. Intro to cGMPs:
The Building Blocks for
GFSI Compliance
Sonia Akbarzadeh
Founder & Partner
Food Industry Consulting, Inc.

2. Rajan Gupta
VP Customer Success
TraceGains
Sonia Akbarzadeh
Founder & Partner
Food Industry Consulting, Inc.

3. Introduction to cGMPs
Presented by:
Sonia Akbarzadeh Msc, Eng.
Food Safety Consultant

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)

5. Introduction to GMPs
Internationally recognized standards:
 GMPs in detail
Mandatory requirements:
 Risk assessments
Validation

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

9. Introduction to GMPs
Personnel hazards:
 Sneezing
 Illnesses
 Cuts
 Infections
 Dirty hands
 Dirty clothes
 Jewelry and loose objects

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

16. Introduction to GMPs
Personnel Practices
Traffic patterns (Employees & Visitors)
Site map
Hand washing policy
Uniform policy

17. Introduction to GMPs
Sanitation
oComprehensive system
oEffectively remove
 Food residues
 Soil
 Unacceptable chemical residues

18. Introduction to GMPs
Sanitation
Effective cleaning & sanitizing
Rooms
Utensils
Equipment
Avoid cross contaminating

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

23. Introduction to GMPs
Water Potability
Testing for:
 Heavy metals
 Bacteria
 pH
 Turbidity

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

31. Introduction to GMPs
Equipment and Preventive maintenance
Annual Master PM schedule
Preventive maintenance SOP
Maintenance checklist
Work orders
Post maintenance sanitation procedure
Documenting & investigating equipment failures
Control of temporary repair
Verification

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

33. Introduction to GMPs
Receiving/Storage/Shipping
Storing:
Sanitary condition
Proper environmental conditions
(Temperature & humidity)
Designated areas
Site map

34. Introduction to GMPs
Receiving/Storage/Shipping
Conditions vary depending on :
 Type
 Nature
 Temperature
Such as,
• Bulk
• Bagged
• Refrigerated
• Frozen
• Packaging materials

35. Introduction to GMPs
Receiving/Storage/Shipping
Approving contract transport
o Freight questionnaire
o Audit
Truck designated for only food
Not for metals, chemicals or glass
transportation

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

44. For more info
please visit us:
www.food-industry.ca

45. Automating
Supplier
and Quality
Management

46. TraceGains Products
Specification Publishing
Create, maintain, and
publish your company’s
unique specifications to
ensure compliance on
incoming ingredients.
Supplier Compliance
Automate lot-by-lot
compliance across
purchasing, COAs,
receiving, testing, and
plant floor.
Finished Goods COAs
Generate finished goods
COAs, manage
customer-specific
formats, and send to
customers on demand.
Supplier Management
Automatically manage
supplier qualification,
documents, and
relationships.
Quality Management
Automate HACCP /
HARPC and comply
with GFSI, FSMA,
safety, and quality.

47. Supplier Analysis
& Scorecarding
TraceGains Supplier Management
To-do Lists,
Corrective Actions
Access Anywhere,
Anytime
Allergens OrganicAudits KosherNutritionSupplier
Qualification
FSMA, GFSI, 365 Audit Ready™
C.O.O.L. Specifications
24/7 Monitoring
eNotifications
Labeling
(e.g., Genesis)

48. TraceGains Quality Management
To-do Lists, Alerts,
Corrective Actions
Trends & Graphs
Access Anywhere,
Anytime
CCPs
Pre-op Sanitize,
Calibrate, etc.
Verify CCPs Automate FSMA, GFSI
Audits & Records
GFSI
Documents
FSMA, GFSI, 365 Audit Ready™
Pre-Shipment
Checkoff
Staff Training

49. Automation Solves Many Problems
GFSI
Labeling
FSMA
Audits

50. Rajan Gupta
rajan.gupta@tracegains.com
www.tracegains.com
Sonia Akbarzadeh
Sonia@food-industry.ca
888-406-5554
www.food-industry.ca