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  Educate employees on the Product
Safety & GMP Principles

 Create awareness of the importance in

following our product safety& GMP
requirements.

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 Product Safety is NOT the same as Plant Safety

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 Food safety is used as a scientific
method/discipline describing handling,
preparation and storage of food in the way that
prevent food-borne illness which can cause
injury/illness/ or death
Food Safety Regulations include:

 Food safety management system

 Hazard Analysis and Critical Control Points (HACCP)
 Good Manufacturing Practices (GMP)

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 The Food Safety Code requires that
you:

• Know your company’s product safety

policy

• Document work activities (say what you do)

• Follow the documents (do what you say)

• Maintain records (prove it)

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 Nyagatare maize processing factory is
committed to providing safe, high quality food
service packaging which meets or exceeds our
customers’ expectations.

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 Hazard Analysis and
Critical
Control Points (HACCP)
A preventive approach to food
safety from
biological, chemical, and
physical hazards
in the production process that
can cause
the finished product to be
unsafe.
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 Biological Hazards: harmful bacteria, viruses
or parasites.
Sources: skin, nails, sores, clothing

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 Chemical Hazards: compounds that can cause
illness or injury due to exposure.
Sources: cleaning agents, pest sprays

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 Physical Hazards: foreign objects that can
cause harm to product.
Sources: glass, jewelry, food

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 Good Manufacturing Practice (GMP)
A system for ensuring that products are produced
and controlled according to quality standards.

GMPs:
 Require employees to understand the aspects of
product safety.
 Requires employee’s commitment to perform their
jobs as trained and always comply with GMP Rules.

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 Hair nets and beard
nets must be worn.
If you have hair on your head or
face, you need to cover it!

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 No Jewelry or watches
(plain wedding band and medical bracelets
are allowed).

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 No false
eyelashes, false
nails, strong perfume,
jewels, no nail
polish.

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 In production…
No…
Chewing gum or tobacco
Spitting
Eating
Candy, mints, cough drops
Cell phones
Audio headsets
Water bottles
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 (No glass or ceramic types of containers are allowed).

Pens with removable

caps are not permitted
in production.

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 Hand Washing is required after:
 Visiting the restroom
 After coughing, sneezing, using a tissue, using tobacco,
eating, or drinking
 After touching bare human body
parts other than clean hands
 Working on machinery
 Handling garbage
 Returning from breaks
or lunch

Wash hands whenever they

are dirty!

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 Hand Sanitizer
 Hand sanitizer must be used
 Located in every production and
throughout the facility
 Required every time an
employee* enters a production
line before contact with product.
*Employee means ALL employees
(packers, leads, supervisors, quality, process
technicians, process assistants, maintenance,
engineers, etc.)

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 Employees with visible cuts, infected cuts,
boils, or sores are not permitted to handle raw
or finished product unless properly covered
with a colored bandage.

Employees with infectious disease

are not permitted to handle raw or
finished products.

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 Lockers and designated personal
storage bins are provided for
storage of employee’s personal
items.
• Not allowed
Food or drink

• Allowed
Keys, pens, notepads,
jackets
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 Employee must wear ear
protection, safety shoes and helmet
in the production area.

Ear plugs are not required in the warehouse or office areas.

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 Clothing
No…
 Items in shirt pockets
 Clothing that exposes lower torso
 Belts with extra parts or big
buckles
 Clothing with glitter, jewels,
sequence, etc.
 Items behind held behind ears,
in hair, or attached to shirt collar
 Clothing should be clean and in
good repair.
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 Smoking
To prevent smoke from entering the facility and
contaminating product, there are 2 approved
smoking areas:

1. Yellow area next to the

chiller platform
2. SW corner by Shipping
Dept.
Cigarette butts are NOT
allowed on the ground.
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 Facility Security
Security measures are in place to protect our product,
the company, and our customers.

 All employees must enter/exit through the

employee door only
 Employees must have their badge
 Propping open doors is not allowed
 Report any unauthorized persons in the
facility without a badge
 Notify a Supervisor for any signs of
tampering or criminal acts on the product,
process, or facility

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 Trash
 Bags of garbage are not allowed on the production
or warehouse floor
 Garbage must be held in a approved and labeled
container
 Lids must remain closed on garbage containers and
dumpsters
 Use rag containers must remain closed
 Garbage from the break room must
be taken directly to the dumpsters
 No garbage on tool carts, racks, or equipment
 Do not use product cases as garbage collectors

Keep your area clean at all times!

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 Pest Control
 Doors and screens must be closed at all times
 Functional screens in good repair must be
installed on all windows, doors, and bays which
are left open
 Pest bait stations and fly lights should not be moved or
damaged
 Report missing or non-functional bait stations and fly lights to
your Supervisor
 Observed pests in the facility are to be logged
on the Pest Sighting Log (outside the Quality office)
 Remove larger pests from the facility as quickly and
humanely as possible. A professional may be needed
to remove a potentially dangerous animal.
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 Compressed Air
Air hoses are not to be used for general cleaning
(floors, platforms, etc.) as it blows dust and dirt which will
contaminate product.
 Cannot be used on extruders, formers, electrical
cabinets
 Cannot be used to clean floors
 Cannot be used to blow dust
off your uniform
 Can be used to clean out machine
and hoppers
 Can be used to clean inside the bins
 Can be used to blow of filters (outside only)
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Chemicals
 No open or unattended
chemicals allowed in
Production
 All chemicals used must
be in a properly labeled
container

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 Many, many buckets…
Blue buckets – recyclable clean lids
only
Red buckets – maintenance items
Yellow buckets – Raw material &
regrind labeled for contents
Grey buckets – Product which has
made contact with the floor or otherwise
deemed as dirty

All buckets must remain closed with lid!

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 Scrap
Contaminated lids, plastic sheet and
packaging materials must be
scrapped.

Scrap should be placed

in the dirty material.
Scrap cannot
be mixed with garbage.
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 When a line is not in use,
all areas of the line which
come in contact with
product must be
covered with
plastic/tarpaulin.
Upon line start up,
packing table must
be sanitized.
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 Equipment parts removed
during maintenance must
never touch the floor.

Spere parts removed

from the line must
be placed on a
table.
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 Bags used to package
product cannot be placed on
the floor. They must be kept
on pallets, stands, or table.

Used bags or other containers

removed cleaning
chemicals/lubricant must be
disposed
of. However, chemical containers
present contamination, oil or
grease must be kept separately.

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 Labeling for identification

 Containers used for storing tools,

equipment, liquid, etc.
 Approved garbage containers
 Waste collection bins
 Bags that contains wastes
 Raw material
 Finished product
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 Protecting Product
What needs to be covered?

 Plastic rolls
 Byproduct bins/bags
 Buckets
 Packing tables
 Finished product
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 Glass & Brittle Policy
Report any broken or cracked
glass and plastic to the Supervisor and
do always inspect.
 Sight glass of equipment
 Lights
 Window and doors with glass
 Other part of machine with glass
 Plastic containers used
 Plastic material installed on machine

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 Cleaning Color Code Program
All mops, brooms, shovels, air hoses,
dust pans, etc. must be stored off the
floor and
labeled for
their
approved
area of use.

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 Cleaning & Sanitation Program
Cleaning and sanitation must be practiced to avoid
contamination of product. Areas included in the cleaning
program:

 Break room
 Garbage areas, facility ground
 Restrooms
 Floors, walls, ceilings
 Fans, lights
 Production equipment
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 Documentation
All departments must maintain proper
documentation and records.

Documents and records:

 Will be inspected during audits
 Must be controlled
 Must be consistent across shifts
 Are more effective saved electronically

If it’s not written down, then it

didn’t happen!
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 Records

Hard copy records should

always be shown in ink.
 Pencil entries are not allowed
 White out/correction products
should not be used

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 Summary
 Know you product safety policy
 Be familiar with standard requirement
 Follow procedures that apply to your job
 Document your activities
 Look out for product hazards in the facility
 Follow GMPs at all times

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 RS 184: 2017

Food safety system based on hazard analysis and critical

control points (HACCP) — requirements for any
organization in the food chain

SIGHT AND LIFE

September 2022

4
2
Clause 1 Scope

Clause 2 Normative references

Clause 3 Definitions

Clause 4 Documentation requirements

Clause 5 Management responsibility

Clause 6 Pre-requisite programmes

Clause 7 Corrective action

Clause 8 Application of HACCP Principles

 A systematic preventative system of controlling food safety
hazards so as to ensure the safety of food at the time of
human consumption.

 Critical Control Points:

 A Critical Control Point (CCP) is a point, step, or procedure
in a food manufacturing process (food chain) at which
control can be applied and, as a result, a product safety
hazard can be prevented, or reduced to an acceptable level.

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Product Safety Hazard –

 chemical,
 biological or
 physical agent in the product or condition of the product
with a potential to cause quality defect or an adverse
health effect.
 Reduces Dependence On Finished Product Sampling &
Testing
 Hazard Analysis And Critical Control Points
 It Uses A Preventive Approach To Food Safety
ORIGIN OF HACCP
From the NASA work, Pillsbury developed the
philosophy

If one could understand how a product becomes

unsafe, one can prevent the specific failure that
causes the product to become unsafe in the first place
 SCOPE OF HACCP
 GROWING
 HARVESTING
 PROCESSING
 MANUFACTURING
 DISTRIBUTING
 MERCHANDISING
 PREPARING
 CONSUMPTION
4.1 HACCP manual
4.1.1 Organizations are to establish and maintain a HACCP
manual that includes:
 HACCP scope
 Documented procedures established for the HACCP, or
reference to them
 PRP procedures or reference to them
The scope of HACCP shall specify
 the products or product categories,
 processes and
 production sites that are addressed by the food safety system
include all activities of the organization for which it is responsible
and can be held liable.
5.1 General
Top management shall provide evidence of its commitment to the
development and implementation of the HACCP based food safety
system and to continually improving its effectiveness by:

 Food safety policy,

 Resources,

 Clear communication about food safety issues

 Conducting management reviews

 Defining the responsibility and authority of the HACCP team leader.

5.2 Establishing the food safety policy

 is appropriate to the role of the organization in the food chain,
 conforms with both statutory and regulatory requirements
5.2 Establishing the food safety policy

 Is communicated, implemented and

maintained at all levels of the organization,
 Is reviewed for continued suitability,
 adequately addresses communication, and
 Is supported by measurable objectives.
The management is committed to offer fine, safe food

In pursuit of this commitment, we shall:

 Implement and maintain a Food Safety Management System
 Identify, evaluate and control all potential food safety
hazards within the defined scope
 Ensure all employees are continuously trained on food
safety
 Ensure effective communication to responsible parties on
food safety related issues.
 Conform to applicable statutory and regulatory
requirements and mutually agreed food safety requirements
of the intended users
This policy which is supported by measurable objectives shall be reviewed
during management reviews for continued suitability and communicated to
all employees and other relevant interested parties.
 Is communicated, implemented and
maintained at all levels of the organization,
 Is reviewed for continued suitability,
 adequately addresses communication, and
 Is supported by measurable objectives.
5.3 Responsibility and authority
Top management shall ensure that responsibilities and
authorities are defined and communicated within the
organization to ensure the effective operation and
maintenance of the food safety system.

5.4 Appointment of the HACCP team and team leader

Management shall ensure the establishment of criteria for the
selection of team members including the team leader to assist
with the study of the HACCP system.
(The team shall be multidisciplinary)
5.4.1 HACCP team
The team shall be multidisciplinary withy members shall be
drawn from each part of the organization whose role may
impact on food safety (production, purchasing, finance,
technical, engineering, quality and distribution)
The team shall consist of personnel with specific product
knowledge.
5.4.2 HACCP team leader
5.4.2.1 A HACCP team leader shall be appointed and act as the
HACCP system team leader.
His roles shall include:
 To ensure that the HACCP system is established,
implemented, maintained and continually improved in
accordance with the requirements of this standard.
 To report on the performance of the HACCP system to
management and any need for improving the system.
 To manage a food safety team and organize its work.
 To ensure relevant training and education of the food safety
team members.

5.4.2.2 The HACCP team leader shall be adequately trained

in the requirements as provided for in this standard.
 5.5 Resources
The team leader shall assess which resources are needed for the HACCP

implementation:
 Management shall provide necessary resources (time, competent personnel,
suitable and adequate infrastructure, work environment, equipment and
funding)
 Appropriate records of education, training, skills and experience shall be
maintained
 Effectiveness of training shall be evaluated

5.6 Communication
Effective arrangements for communicating internally and externally (suppliers,

customers
Issue : Apr 2020 and regulators) on issues having an impact on food safety.
3

They shall be cconducted at planned intervals and records

shall be kept

 Management review shall include at least the following:

 matters arising from previous management reviews;
 a review of the effectiveness of CCP monitoring and
failure of CCPs;
 a review of corrective actions and product disposal;
 HACCP plan verifications;
 HACCP plan reviews and validation of changes to the
HACCP plan;
 a review of customer and consumer complaints;
 a review of recall incidents;
 recommendations for improvement;
 resource needs;
 review of the audit findings;
 a review of suitability of the HACCP policy,
 where applicable, interrelation with other
management systems.
 7.1 The organization shall ensure the development of a
documented correction and corrective action system.
7.2 The system shall define the requirements for:
a) take immediate action (correction)
b) review of non-conformities;
c) determination of the cause of the non-conformity;
d) evaluation of the need for action to ensure that the non-
conformity does not recur;
e) determination and implementation of the action needed;
f) recording of the results of the action taken (correction),
and
g) reviewing the effectiveness of the corrective action taken.

Issue : Apr Issue

2020 : Apr 2020 MMC/INTAS- ISO 22000:2018 FSMS & PRPS Awareness Training Course
7.3 The correction and corrective action system shall, as a
minimum, address the following:
 customer and consumer complaints;
 internal audit reports;
 non-conformity reports;
 outcome of management reviews;
 outcome of HACCP plan reviews;
 results from HACCP plan validations and verifications;
and
 failure of CCPs.
HACCP Principles is comprised of 12 stages
 5 First stages (pre-steps)
1. Assemble the HACCP team
2. Describe the product
3. Identify intended use
4. Construct flow diagram
5. On-site verification of flow diagram
7 stages (Principles) of HACCP implementation

1. Conduct Hazard analysis

2. Determine the Critical Control Points (CCP)
3. Establish critical Limits
4. Establish Critical Control Point (CCP) monitoring
5. Establish Corrective actions
6. Establish validation, verification and review procedures
7. Record keeping &documentation
Stage 1. Assemble the HACCP Team
 Rules and guidelines for:

 team meetings

 criteria used for decision making processes.

 Methodology for:
 Determination of hazards and CCPs;

 Reporting on the HACCP status;

 Establishment of procedural requirements or integration

with other relevant management system procedures.
 Stage 2. Describe the product
 A product shall be described at least in terms of:
 Type and composition (biological, chemical and physical),

 Relevant legislation and standards,

 Handling, processing, presentation or packaging, storage

 Distribution conditions

 Shelf life

 Safety
 Stage 3. Identify the intended use
 Direct consumption or further processing

 Misuse or abuse

 Targeted sensitive population/consumers such as elderly,

infants…
 Stage 4.Construct a process flow diagram
 Details of all process activities:
 Inputs into the process in terms of raw materials

 Conditions of production and packaging

 Output from the process (e.g. waste, by-product)

 Product-in-progress

 Rework

 Rejected products
Stage 5. Arrange an on-site confirmation of the flow diagram
 Confirmation shall be done the HACCP team
 Confirmation process flow diagram is done through
conducting on-site:

 Observe process flow

 Sample activities

 Interviews

 Routine / non routine operations

The 7 HACCP principles

Principle 1. Hazard analysis

 Identification of hazards through the process flow :

 A hazard must be controlled if it is likely to occur, and/or
likely to result in an unacceptable risk to consumers.
Principle 2: Determination of Critical Control Points (CCPs)

CCPs are steps in the process flow where Significant hazards are

identified and can be prevented, eliminated or reduced to

acceptable levels
Refer to CCP Decision Tree
Principle 3: Establish critical limits
For each CCP, establish minimum or maximum limits

Principle 4: Establish CCP monitoring system

A planned series of observations or measurements need to
be taken to assess whether a CCP is within critical limits.

Principle 5: Establish corrective actions

The aim is to correct and eliminate the cause of the problem
and bring CCP back under control
Principle 6: Establish validation, verification and review
procedures
Validation-
Obtaining evidence that the elements of the HACCP plan are
effective
Verification-
The application of auditing methods, procedures, tests and
other evaluations, in addition to monitoring, to determine
compliance with the HACCP plan.
Potential factors that can influence HACCP plan review:
•Report from the marketplace; Change in raw materials or
product formulation; Change in the food handling process
activities;
Principle 7: Establish control of documents and records
 The procedure for document control shall be
established

 Procedure for the control of records shall be

established and address identification, collection,

storage, protection, retrieval records etc.

 Records
.
 List of product ingredients and associated materials

 A detail process flow diagram needs to be available

 Plant layout and positioning of machinery
 List of hazards at each process step

Process Nature of Hazard Control measure

step hazard
Receiving Physical weed Sorting

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 Hazard Analysis processes

Seve Likeli Impact Signific. HACCP

rity - Team
hood. recm
Process step Hazard

Grinding P 3 2 High S CCP

Mixing

Etc….

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2 ISO 22000:2018

Severity (Level of control)

1 (Low) 2 (Medium) 3 (High)

Likelihood 1 (Low) 1 2 3
of
occurrenc 2 2 4 6
e (Moderate)
3 (High) 3 6 9

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2 ISO 22000:2018

Decisions made at a certain level of R,

If R is 1- 2 Negligible (NS)----------PRP
3-4 Minor impact (NS)-------OPRP
6- 9 Major impact (S)……….CCP
12- Severe impact (S)……….CCP

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2 ISO 22000:2018

S- Determine where to control the hazards

NS- Controlled at this step and records kept
Hazard Analysis involves Risk Assessment
Risk –Estimation of Hazard occurrence extent
Risk is a function of Likelihood of hazard occurrence and
control level (severity level)

R=L×C(S)

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2 ISO 22000:2018

R SEVERITY POSSIBLE CONSQUENCES RMKS

1 Negligible Unnoticed PRP
2 No impact Will go unnoticed PRP
3 Minor Irritate customer or boss OPRP
impact
4 Signif. Formal complaint, breach of OPRP
impact trust
6 Major Loss of customer acc,damage CCP
impact company image
9 Major May lead to considerable CCP
impact material/financial loss or
litigation
12 Severe Death/ business closure CCP
impact
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2 ISO 22000:2018

Risk Assessment in Feed Production process

Process Hazard Critical Prob Contr Risk Level

Step Limit able Level
level
Ingredi Foreign -Nil 2 1 2 (PRP)
ents matter
Loading 2 2 (PRP)
-Foreign -Nil 2 2 4 (OPRP)
Grindin matter
g

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2

Risk Assessment in the Food Production process

Process Hazard Critical Limit Probab. Control Risk Level

Step Level Level

Mixing. Chemical -As per spec 1 2 4 (OPRP)

-Metal - Nil 3 1 3 (PRP)
-Micro -As per spec 3 1 3 (PRP)
personnel

Temperin -Lubr oil - MSDS 3 1 3 (PRP)

g -Dust - Nil 2 1 2 (PRP)
-Person -As per spec 3 1 3 (PRP)
micro

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2

Risk Assessment in the Food Production process

Process Hazard Critical Probab ContrLe Risk

Step Limit .level vel Level
Warehou -Micro ≤104cfu/ 2 1 2 (PRP)
se -Hair,etc ml 2 1 2 (PRP)
Dust Nil 3 1 3 (PRP)
Nil

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2

Determine CCPs- Decision Tree

Process Signfic. Q1 Q2 Q3 Q4 Q5 CCP HACCP Team

step hazard Notes

Y Y N Y Y CCP Why CCP

Not Hazard
CCP control at
step……

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2

Selection and categorization of control measure(s)

Based on the hazard assessment, the organization
shall select an appropriate control measure or
combination of control measures that will be capable
of preventing or reducing the identified significant
food safety hazards to defined acceptable levels.

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2

8.5.3 Validation of
control measure(s) and combinations
of control measures

The food safety team shall validate that the selected

control measures are capable of achieving the intended
control of the significant food safety hazard(s).

This validation shall be done prior to implementation of

control measure(s) and combinations of control
measures to be included in the hazard control plan

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2

8.5.4 Hazard control plan (HACCP/OPRP plan)

8.5.4.1 General
The organization shall establish, implement and
maintain a hazard control plan.

The hazard control plan shall be maintained as

documented information and shall include the
following information for each control measure at
each CCP or OPRP:

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
Process Step CCP No Hazard Critical Limit Control Monitoring Monitoring Corrective Responsible
Measure Frequency Action
 2

Determination of critical limits and action criteria

Critical limits at CCPs and action criteria for OPRPs shall be
specified.
The rationale for their determination shall be maintained as
documented information. (see decision tree and risk
assessment table)
Critical limits at CCPs shall be measurable. Conformance
with critical limits shall ensure that the acceptable level is not
exceeded.
Action criteria for OPRPs shall be measurable or observable.
Conformance with action criteria shall contribute to the
assurance that the acceptable level is not exceeded.

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
  Establish Critical Limits
A value of physical, chemical or biological
nature which separates acceptability from
unacceptability.
CL indicate absolute tolerance for safety.
Critical limits are not necessarily equal to
existing processing parameters.
Criteria often used include measurements of
temperature, time, moisture level, pH, activity
of water, available chlorine, sensory
parameters.
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 2
DISPLAY CRITICAL LIMITS NEXT TO CCP’s
HOW TO SET CRITICAL LIMITS
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INDICATE ABSOLUTE TOLERANCE FOR SAFETY
CRITICAL LIMITS NOT NECESSARILY EQUAL TO EXISTING
PROCESSING PARAMETERS

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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8.5.4.3 Monitoring systems at CCPs and for OPRPs

At each CCP, a monitoring system shall be
established for each control measure or combination
of control measure(s) to detect any failure to remain
within the critical limits.

The system shall include all scheduled

measurements relative to the critical limit(s).

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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8.5.4.4 Actions when critical limits or action criteria are not

met
The organization shall specify corrections (see 8.9.2) and
corrective actions (see 8.9.3) to be taken when critical limits
or action criterion are not met and shall ensure that:
a) the potentially unsafe products are not released (see
8.9.4);
b) the cause of nonconformity is identified;
c) the parameter(s) controlled at the CCP or by the OPRP is
(are) returned within the critical limits or action criteria;
d) recurrence is prevented.

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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PURPOSE:
The purpose of this workshop is to practice using an appropriate framework in
conducting hazard analysis and drafting a HACCP Plan and an OPRP plan for an
organization
 INSTRUCTIONS FOR DELEGATES:
Form teams of 3-5 people per group.
Choose one of these Processes/activities
 Storage of raw materials
 Transportation of finished
 Purchasing of raw materials
Using the formats provided, name at least four hazards that must be addressed to
ensure food safety and analyze/assess them.
Using the format provided prepare a draft HACCP Plan for the organization
Using the format provided prepare a draft OPRP plan for the organization
Prepare to share your work in class.

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
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8.5.4.5 Implementation of the hazard control

plan

The organization shall implement and maintain the

hazard control plan, and retain evidence of the
implementation as documented information.

Hazard Control Plan: HACCP PLAN OR OPRP PLAN

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 RECAP: Hazard control plan must contain, as a minimum,
the following information for all identified CCPs and
OPRPs:
 what food safety hazard are you controlling with this CCP or
OPRP
 what measure have you put in place to do so
 the critical limit/s or action criteria in place that can’t be
exceed
 how do you monitor this activity
 which corrections and corrective actions will be carried out
if critical limits or action criteria is not met
 who is responsible for this activity (defined responsibilities
and authorities)
 what records do you maintain as monitoring evidence
Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING
 Following the establishment of the hazard control plan, the
organization shall update the following information, if
necessary:
a) characteristics of raw materials, ingredients and product-
contact materials;
b) characteristics of end products;
c) intended use;
d) flow diagrams and descriptions of processes and process
environment.
The organization shall ensure that the hazard control plan
and/or the PRP(s) are up to date.

Issue : Apr 2020 MMC/INTAS- ISO 22000:2018 AND RS 184 HACCP REQUIREMENTS AND DOCUMENTATION TRAINING