HACCP Advantage Program Manual, Ontario, Vol1
HACCP Advantage Program Manual, Ontario, Vol1
HACCP Advantage Program Manual, Ontario, Vol1
Authors
Molly Elliott, Troy Jenner, Pat Johnson and Cynthia Menyhart, Ontario Ministry of
Agriculture, Food and Rural Affairs (OMAFRA).
Editors
Pat Johnson, Jennifer Aitkens, Vivian Webb, Ontario Ministry of Agriculture, Food and
Rural Affairs (OMAFRA).
Acknowledgements
This publication was prepared with the help and assistance of:
Heather Kinnear, Andrea Smallwood, Luis Garcia, Rick Bond, Ontario Ministry of
Agriculture, Food and Rural Affairs (OMAFRA), the Canadian Food Inspection Agency,
Alberta Ministry of Agriculture, Food, and Rural Development, Manitoba Agriculture
and Food, T & R Sargent Farms Ltd., Fulton Food Safety Consultants and IBM Business
Consulting Services.
CONTROL PROGRAMS
P1 Personnel Practices
P1.1 Personnel Practices Program ................................................ 11
P2 Shipping, Receiving, Handling and Storage
P2.1 Shipping, Receiving, Handling and Storage Program .................. 12
P3 Sanitation
P3.1 Sanitation Program ............................................................ 13
P4 Equipment Maintenance
P4.1 Preventive Maintenance and Calibration Program ...................... 14
P5 Pest Control
P5.1 Pest Control Program ........................................................ 15
P6 Recall
P6.1 Recall Program ................................................................ 16
P7 Water Safety
P7.1 Water Treatment Program ................................................... 17
P7.2 Water Safety Monitoring Program ......................................... 18
TRAINING
T1 Personnel Practices
T1.1 Personnel Practices Training ................................................ 21
T2 Shipping, Receiving, Handling and Storage
T2.1 Shipping, Receiving, Handling and Storage Training .................. 22
T3 Sanitation
T3.1 Sanitation Training ............................................................ 23
T4 Equipment Maintenance
T4.1 Preventive Maintenance and Calibration Training ...................... 24
T5 Pest Control
T5.1 Pest Control Training ........................................................ 25
T6 Recall
T6.1 Recall Training ................................................................ 26
T7 Water Safety
T7.1 Water Treatment Training ................................................... 27
T7.2 Water Safety Monitoring Training ......................................... 28
T8 Critical Control Point
T8.1 Critical Control Point Training ............................................. 29
T9 Process Technology
T9.1 Equipment and Specialized Process Training ............................ 30
Table of Contents
OPERATIONAL CONTROLS
O1 Personnel Practices
O1.1 Personal Hygiene/Practices ................................................. 33
O1.2 Hand Washing ................................................................. 34
O1.3 Clothing/Footwear/Headwear ............................................... 35
O1.4 Storage – Clothing/Utensils/Equipment ................................... 36
O1.5 Injuries and Wounds ......................................................... 37
O1.6 Evidence of Illness ........................................................... 38
O1.7 Access and Traffic Patterns ................................................. 39
O1.8 Chemical Use .................................................................. 40
O1.9 Chemicals Used During Operations ....................................... 41
O2 Shipping, Receiving, Handling and Storage
O2.1 Conveyance Vehicles ......................................................... 42
O2.2 Loading and Unloading Practices .......................................... 43
O2.3 Received Products ............................................................ 44
O2.4 Shipping Conditions .......................................................... 45
O2.5 Returned and Defective Food Products ................................... 46
O2.6 Allergen Control .............................................................. 47
O2.7 Packaging ...................................................................... 48
O2.8 Storage Practices .............................................................. 49
O2.9 Chemical Storage ............................................................. 50
O2.10 Waste Management ......................................................... 51
O3 Sanitation
O3.1 Cleaning and Sanitizing ...................................................... 52
O3.2 Pre-operational Assessment ................................................. 53
O4 Equipment Maintenance
O4.1 Preventive Maintenance and Calibration Monitoring ................... 54
O5 Pest Control
O5.1 Pest Control Monitoring ..................................................... 55
O6 Recall
O6.1 Product Code/Labelling Monitoring ....................................... 56
O6.2 Mock Recalls ................................................................... 57
O7 Water Safety
O7.1 Water Treatment Monitoring ............................................... 58
O7.2 Water Safety Monitoring .................................................... 59
ENVIRONMENTAL CONTROLS
E1 Establishment Location and Construction
E1.1 Property and Surroundings .................................................. 63
E1.2 Building Exterior .............................................................. 64
E2 Establishment Design
E2.1 Cross-contamination Control ................................................ 65
E2.2 Personnel Facilities ........................................................... 66
E3 Establishment Interior
E3.1 Internal Structures and Fittings ............................................. 67
Table of Contents
E3.2 Lighting ......................................................................... 68
E3.3 Lighting Fixtures .............................................................. 69
E3.4 Air Quality and Ventilation ................................................. 70
E3.5 Drainage and Sewage Systems .............................................. 71
E4 Equipment
E4.1 Equipment Design, Construction and Installation ....................... 72
E4.2 Waste Containers and Utensils ............................................. 73
E4.3 Hand-washing Stations ....................................................... 74
E5 Water Supply
E5.1 Adequate Supply and Protection of Water, Ice and Steam ............ 75
HACCP Advantage
HACCP Advantage Introduction ....................................................... 79
Form #1: Product Description ..................................................... 83
Form #2: Ingredients and Incoming Materials .................................. 84
Form #3: Flow Diagram ............................................................ 85
Form #4: Plant Schematic .......................................................... 86
Form #5: Hazard Description and Critical Control Point Determination .. 87
Form #6: Flow Diagram with Critical Control Points ........................ 90
Form #7: Uncontrolled Hazards .................................................. 91
Form #8: HACCP Matrix .......................................................... 92
GMP Advantage
Good manufacturing practices (GMPs) are the foundation of any effective food safety program. GMP Advantage
addresses the hazards associated with personnel and the processing environment. In addition to the prerequisite
programs contained in the original HACCP Advantage, it contains a new Operational Control Standard for “Mock
Recalls". The “Shipping, Receiving and Storage” sub-group has also been expanded to include handling.
HACCP Advantage
HACCP Advantage includes the GMP Advantage components as well as eight HACCP plan forms. With HACCP
Advantage you have the tools you need to deal with product and process related hazards that are specific to your facility
and products, as well as the hazards related to personnel and the processing environment already controlled by the
GMP Advantage.
While each step increases food safety – and potentially improves marketability for your products – the program you choose
or how far you proceed will depend on your market reach, supplier demand and the level of food safety risk in your
operation. The Canadian General Standards Board provides certification for each level of the HACCP Advantage Programs
within Ontario.
Resources
It is possible to implement any of the three programs using just the HACCP Advantage Program Manual, although some
operators may find specialized advice from an outside consultant to be useful. The HACCP Advantage Guidebook,
produced as a companion to this manual, can help you resolve many common problems. Copies of the Guidebook can be
obtained by calling 1-888-466-2372 extension 64752 or by visiting the Ministry’s website at www.omafra.gov.on.ca
www.omafra.gov.on.ca.
A comprehensive food safety management system depends on sound management skills and continual monitoring. It also
requires extensive knowledge of the facility into which the program is being implemented, a solid understanding of the
principles of food safety and of HACCP as well as an awareness of the hazards associated with the food being produced.
The page for each standard is organized under the following headings:
• What is the standard? – This is the outcome you must achieve in order to meet the standard. You must design
and implement an effective program that meets the intent of the standard.
• Which regulations apply to this standard? – Some commodity areas are regulated and have additional food
safety expectations associated with a given standard. These regulatory references direct your attention to the
regulatory requirements.
• What are the risks? – This section explains why the standard exists and what hazard(s) it is meant to control.
• How can you meet the standard? – This section outlines suggested control measures frequently used in the
food processing industry.
• Are you in conformance? – This section outlines suggested monitoring procedures you can implement to ensure
the standard is being met.
Apart from the name changes noted above, there are a few new changes to the GMPs. They include:
3. A new standard, O6.2 Mock Recalls, has been added to Operational Controls. This standard requires mock recalls
to be scheduled, performed and documented to test the effectiveness of the documented Recall Program (P6.1).
Facilities that are currently HACCP Advantage-certified will have to add this new standard to their program
prior to their next audit.
4. All references to the Meat Inspection Act have been replaced with references to the new Meat regulation
(O. Reg. 31/05) under the new Food Safety and Quality Act, 2001. All non-federally registered abattoirs and
free-standing meat plants must meet this regulation.
5. The “Shipping, Receiving and Storage” sub-group has been expanded to include handling as well and is
now entitled “Shipping, Receiving, Handling and Storage”. These standards ensure that ingredients, food,
packaging materials and finished products are always handled in a manner that is safe and prevents
contamination.
The HACCP Advantage Guidebook will provide you with more specific guidance, along with a number of examples, to
help with the implementation of the GMP Advantage program.
P2 Shipping, Receiving, Handling and Storage T2 Shipping, Receiving, Handling and Storage
P2.1 Shipping, Receiving, Handling and Storage Program T2.1 Shipping, Receiving, Handling and Storage Training
P3 Sanitation T3 Sanitation
P3.1 Sanitation Program T3.1 Sanitation Training
Water, ice and steam can be a source of biological or chemical contaminants. Since water, Other:
ice and steam can be used for a variety of purposes (e.g. sanitation, hand washing, ingredient, N/A
processing aid), it is important to perform water sampling and testing to confirm potability.
Potential water contaminants include bacteria (e.g. E. coli) and chemicals (e.g. boiler
chemicals).
Poor or improper establishment sanitation can lead to contamination (e.g. bacterial Dairy:
growth, cleaning chemical residues). Improper chemical concentrations, application or N/A
rinsing procedures can lead to contamination of food with sanitation chemicals. Proper
training of sanitation employees reduces the risk of biological, chemical and physical Other:
contamination of food. N/A
The potential for contamination of food, ingredients, packaging materials and food contact Other:
surfaces by microorganisms and physical contaminants is greatly increased if activities Health Protection and Promotion
such as eating, drinking, gum chewing, use of tobacco, jewelry wearing or spitting are Act (Ontario) O.Reg. 562, s.65;
practiced in food handling areas. Foreign objects found in food products can lead to s.67
consumer complaints or injuries. Personnel who do not maintain an appropriate degree of
personal cleanliness can contaminate food.
Personnel are a common source of bacterial contamination of food, ingredients, packaging Other:
materials and food contact surfaces. Since allergens can be carried on the hands of Health Protection and Promotion
food handlers, proper hand-washing procedures must be followed after handling products Act (Ontario) O.Reg. 562, s.65
containing allergens. Proper and frequent hand washing helps to reduce the potential for
bacterial contamination.
Chemicals used during operations can contaminate food, ingredients, packaging materials, Dairy:
food contact surfaces and personnel if chemical handling, mixing and storage activities are Milk Act (Ontario) R.R.O. 1990.
not performed correctly (e.g. chemicals in containers without lids can spill). Overspray of O.Reg. 761.s.43(1)
sanitation chemicals can lead to chemical or biological contamination during operational
cleaning activities. Other:
Health Protection and Promotion
How can you meet the standard? Act (Ontario) O.Reg. 562, s.63;
s.79
• Ensure that chemicals (e.g. sanitation
chemicals, maintenance chemicals,
lubricants, solvents) used in food
handling areas during operations are
stored and handled in a manner that
prevents or minimizes contamination of
food, ingredients, packaging materials or
food contact surfaces.
Contamination or damage of food, ingredients and packaging materials can occur during Dairy:
transportation or during loading or unloading if shipping and receiving procedures are not Milk Act (Ontario) R.R.O. 1990.
properly followed. When loads are not properly handled, loaded or unloaded, contamination O.Reg. 761.s.122(1g)
can occur from a variety of sources (e.g. forklifts can puncture holes in product containers
leading to the introduction of microorganisms or physical contaminants; incompatible products Other:
can cross-contaminate each other). Damage during transportation can result in exposure of N/A
food products leading to contamination and spoilage.
Returned product has left the control of the establishment and may have been subjected to
improper handling (e.g. temperature abuse, poor storage conditions) causing contamination
of the product. Defective or suspect product could also be contaminated. Returned and Dairy:
defective or suspect products that are not controlled can lead to contamination of other Milk Act (Ontario) R.R.O. 1990,
products. O.Reg. 761, s.60; s.62
If water safety monitoring activities are not performed as written in the Water Safety Dairy:
Monitoring Program (P7.2) contaminants may not be detected. Since water, ice and steam N/A
can be used for a variety of purposes (e.g. sanitation, hand washing, ingredient, processing
aid), non-potable water can transfer contaminants (e.g. E. coli) to food, ingredients, food Other:
contact surfaces and personnel. Treated water (e.g. boiler water, chlorinated water, flume N/A
water) can present a source of contaminants if the chemical treatment or treatment process
is incorrectly performed.
If an establishment is constructed of materials that are not durable and suitable for Dairy:
establishment operations, contaminants can enter into the establishment. Inadequate Milk Act (Ontario) R.R.O. 1990.
or poor establishment conditions can create the potential for hazards that compromise O.Reg. 761.s.77(1)
activities performed in the establishment (e.g. damaged roof can lead to entry of rainwater
or pests). Other:
Health Protection and Promotion
How can you meet the standard? Act (Ontario) O.Reg. 562, s.11
• Design and construct the establishment
so that the internal environment is
protected from external contaminants.
If lighting levels are not adequate for the inspection of food or if the light source changes Dairy:
the natural colour of food, then an incorrect assessment of the appearance of the food N/A
may result. If lighting levels are not adequate to perform required tasks (e.g. cleaning
and maintenance of equipment), this can create the potential for biological, chemical or Other:
physical contamination. Health Protection and Promotion
Act (Ontario) O.Reg. 562, s.13
How can you meet the standard?
• Ensure lighting levels are adequate to
properly complete the tasks performed
in each area (e.g. product inspection,
sanitation, maintenance, visual
examination of rooms).
If a light bulb or lighting fixture breaks over exposed food, ingredients, packaging materials Dairy:
or food contact surfaces, then a physical hazard can occur. Milk Act (Ontario) R.R.O. 1990.
O.Reg. 761.s.77(1)
How can you meet the standard?
Other:
• Equip light fixtures and light bulbs
Health Protection and Promotion
suspended over food, ingredients,
Act (Ontario) O.Reg. 562, s.11;
packaging materials and food contact
s.26
surfaces with shatterproof bulbs
or coverings to prevent or minimize
physical contamination in case of
breakage.
• Form #1 now asks users to ensure that their finished product, as well as the
product recipe, meets the requirements of the federal Food and Drugs Act.
• Form #5 has been simplified and the questions on the decision tree clarified to
make it easier to use and understand.
Product name Product type: Product Finished product Label meets Product contains Product Shelf-life of Storage instructions Intended use of the
(e.g. cooked, raw, characteristics: and recipe meets requirements restricted ingredients contains allergens as product (e.g. keep fresh, product: include
processed, ready (e.g. pH, Aw, the requirements of of Consumer as per Food and per Health Canada keep frozen, special delivery
to eat) salinity, state, other Food and Drugs Act Packaging and Drugs Act (Y/N)? Guidelines (Y/N)? humidity control, instructions, special
qualities) (Y/N)? Labelling Act and If yes, list restricted If yes, list allergens. ready to cook) consumer groups
Regulations (Y/N)? ingredients. (e.g. elderly,
immno-
compromised)
Identify potential biological, chemical or physical hazards associated with each. Answer each question and fill in the
boxes with “B” if a biological hazard exists, “C” if a chemical hazard exists and “P” if a physical hazard exists.
List all incoming raw materials/ Is a potential biological hazard Is a potential chemical hazard Is a potential physical hazard
processing aids/packaging materials associated with the item (e.g. associated with the item (e.g. associated with the item? Address
and ingredients by product name. bacteria, parasites)? antibiotic residues, pesticide both metallic and non-metallic (e.g.
residues, allergenic concerns)? environmental concerns – stones,
dirt; foreign material – needles,
bones).
• Number each step in the process and identify if potential biological, chemical or physical hazards are associated with
each step in the process.
- Is a potential biological hazard associated with the step (e.g. bacterial contamination, bacteria on
surfaces, bacterial growth)?
- Is a potential chemical hazard associated with the step (e.g. sanitation residues, chemical
contamination)?
- Is a potential physical hazard associated with the step (e.g. flaking paint, metal on metal contact)?
PLANT SCHEMATIC
• Conduct a plant schematic or floor plan of the facility, identifying all equipment and rooms.
• Indicate on the floor plan the flow of product and people through the facility.
• On the floor plan, identify all potential cross-contamination points, whether biological, chemical or physical.
Some examples include:
- raw and cooked crossover
- allergen products versus non-allergens
- inedible materials and finished product crossover
- crossover of personnel from incompatible areas
Incoming Materials:
Biological
Determination | Plan Name:
Chemical
Physical
Biological
Chemical
Physical
Form #5: Hazard Description and Critical Control Point
Biological
Chemical
Physical
Process Steps:
Chemical
Physical
Biological
Chemical
Physical
Biological
Form #5: Hazard Description and Critical Control Point
Chemical
Physical
Q1. Could a control Q2. Is it likely that Q3. Is this control Q4. Will a subsequent CCP number
INCOMING LIST ALL BIOLOGICAL, CHEMICAL measure(s) be used at contamination with the measure specifically step eliminate the *Proceed to next
MATERIAL/ & PHYSICAL HAZARDS RELATED any process step? identified hazard could designed to eliminate identified hazard identified hazard.
PROCESS STEP TO INGREDIENTS, INCOMING occur in excess of the or reduce the likely or reduce its likely
* If no, not CCP, enter
MATERIALS, PROCESSING, PRODUCT acceptable level or occurrence of the occurrence to an
List all incoming "NO" on this form and
FLOW ETC. could increase to an identified hazard to an acceptable level?
materials, all process proceed to the next
unacceptable level? acceptable level?
steps, all processing Determine if each hazard that has been identified hazard. *If no, CCP. Go to last
aids and all potential identified is fully controlled by prerequisite *If no, not CCP. *If no, go to question column.
*If yes, describe the Proceed to the next (Q4).
points of cross- program(s). *If yes, not a CCP.
control measure and identified hazard.
contamination as *If yes, CCP. Go to last Identify subsequent
*If yes, indicate “prerequisite program” go to question (Q2).
identified in Form #2, *If yes, go to question column. step and
and which section of the prerequisite
Form #3 and Form (Q3). proceed to the next
programs control the hazard. Proceed
#4. identified hazard.
to next identified hazard.
*If no, go to question (Q1).
Chemical
Physical
Biological
Chemical
Physical
Biological
Form #5: Hazard Description and Critical Control Point
Chemical
Physical
• Using Form #3, identify beside the appropriate steps where the critical control points for the HACCP Plan have
been identified.
UNCONTROLLED HAZARDS
• Summarize all biological, chemical and physical hazards in your facility as identified by a "NO' answer in Q1 on
Form #5.
• Indicate how each hazard will be controlled before or after the process:
- cooking instructions
- public education
- use before date
Process CCP Hazard Description Critical Limits Monitoring Procedures Deviation Procedures and Verification Procedures HACCP Records
Step Hazard Corrective Actions
Identify whether the hazard is Define the Identify the following: Identify the following: List records to be
Number
Number as biological, chemical or physical. value(s) that • who is responsible for the task; If monitoring indicates a deviation, • who is responsible for the task; used.
indicated on Number Describe hazard. are acceptable to • what procedure is to be followed; describe: • what procedure is to be followed;
Form #3. sequen
sequentially. maintain the CCP • what observation is to be made or • who takes the corrective actions; • what observation is to be made or
under control. what measurement is to be taken; • what procedures are to be what measurement is to be taken;
• how often the task is to be followed; • how often the task is to be
performed; • where the actions are to be performed;
• where the observations are to be recorded. • where the observations are to be
recorded. recorded.
HACCP Advantage Plus+ is the third step in the HACCP Advantage series of programs. As outlined in the Introduction
to this manual, HACCP Advantage Plus+ includes all the requirements of the GMP Advantage component and the HACCP
Advantage component.
This section of the manual includes 12 new HACCP Advantage Plus+ standards: four standards relating to traceability and
eight standards relating to security.
Traceability and security of the food supply are becoming important issues in the food processing industry. The traceability
standards enables HACCP Advantage Plus+ users to trace ingredients and finished products back to the immediate supplier
and forward to the next customer. This ability to trace food products “one up and one down” is essential to protect
consumers should a food safety crisis occur.
Security of a food processing facility is also very important. Deliberate tampering or adulteration of food can have
devastating and long-lasting effects not only on the health of consumers but also on the image of the company that produced
the implicated food product. Ensuring a secure food processing environment is the best defense against this type of
problem.
Both groups of standards follow the same organizational design as the GMP standards. The numbering format takes up
where the numbering of the GMP standards leaves off.
As with the other standards, you must achieve the stated outcome, implement monitoring procedures and specify corrective
actions and documentation requirements for each standard. When monitoring any traceability or security standard, record
your observations as well as any corrective actions taken to ensure that the standard is met. Documentation should identify
all records that will be generated as a result of monitoring actions.
A specialized consultant may be able to provide you with more specific guidance to help with the implementation of the
HACCP Advantage Plus+ component.
Systematically recording traceability information when receiving food, ingredients and Other:
packaging materials is essential to developing a traceability system and to maintaining the N/A
system’s integrity. Inadequate identification on incoming food, ingredients and packaging
materials or inconsistent recording of traceability information undermines the integrity
of the food traceability system, which can delay the identification of hazardous materials
and/or increase the breadth of a hazard’s impact in the case of an incident.
Tampering or damage in sensitive areas of food processing facilities can have a critical Other:
impact on the safety and suitability of food, ingredients and packaging materials. Sensitive N/A
areas such as laboratories, chemical and hazardous materials storage areas, interior and
exterior food storage areas, wells, water and ice processing equipment, and central con-
trols for airflow, water systems, electricity and gas are susceptible to sabotage that can
compromise the safety and suitability of food, ingredients and packaging materials. For
example, tampering with water treatment systems can result in unsafe finished products.
Restricting access of sensitive areas to only authorized personnel will prevent deliberate
tampering and/or unintentional disruptions.