Haccp gy lluchk Aexa6pp 02, 2010 51 pagcs HAWAII INTERNATIONAL SEAFOOD, INC. FrozenSeafoodProducts HACCP MANUAL Hygiene, Sanitation Standard Operating procedure and HACCP for suppliers Summer 1999 Prepared For: copyright C october 1999 Contents from this document may not be reproduced in whole or in part without the expressed written consent of Hawaii International Seafood, Inc. Page [email protected] manufacturin facilities are audited by the National Marine Fisheries Se PACE 1 orsi pection Program, to verify compliance h o able standards: IJSFDA HACCP • EU (European Unio • TSSA Tasteless Smo l.
Table of Contents ble of Contents Page 2. Introduction personal Hygiene Photo # 1. Workers Using Masks and Gloves. page 3. Example IIIA: Personnel Hygiene Code Sanitation Standard Operating Procedure Page 4. Photos # 2 and # 3. Ice Potability and Thermometer Checks Page 7. Cleaning Schedule page 7. HACCP Plan Page 8. Photo #5 and #6 Packaging Material Handling Page 9. Example: SSOP plan TSSA establishes strict standards and auditing procedures to «CERTIFV products manufactured with «tasteless smoke» and verifry complaince of tasteless smoked products with IJSFDA food safety and labeling requirements. III.
Personal Hygiene All H. I. S. suppliers shall adopt and maintain a Personnel Hygiene Code and training program at each site where H. I. S. products are produced. In-house training on the Personnel Hygiene Code for all staff shall be conducted by qualified management personnel at least annually and individually each time a new staff member is acquired. Personnel Hygiene Code training shall consist of thorough and complete orientation and explanation of the Personnel Hygiene Code to all staff members. This training shall be documented for each staff member by the issuance by the supplier of an in-house Certificate of
Completion for training on the Personnel Hygiene Code for each individual staff member. This Certificate of Completion should be issued only after the individual staff member has passed an oral or written test on the Personnel Hygiene Code. The Personnel Hygiene Code example that follows this page represents the minimum standards required of all suppliers of seafood products for H. I. S. See example III-A on following page. Note on Surgical Masks and Gloves: Surgical masks and gloves, although not required by H. I. S. may be used at the option of the supplier. Ifthey are used they shall e 100% disposable and disposed of each time the individual staff member exits the processing room in which they are used. In addition, gloved hands shall be washed as required in the Personn de prior to putting 20F on gloves and ag hands shall be washed as required in the Personnel Hygiene Code prior to putting on gloves and again after the gloves are on. PHOTO 41 . Workers using masks and gloves. proper protective clothing shall be worn by all personnel in the processing area.
Disposable surgical masks and gloves may be used at the option of the supplier, but must be used properly. page 2 II. Introduction The people at Hawaii International Seafood Inc. (referred to in this Manual as H. I. S. ) are dedlcated to providing consistently high quality and safe seafood products. For this reason we have written this manual as a guide for Our international suppliers. We are dedicated to working closely with our suppliers to achieve Our goal of exceeding international standards for hygiene, sanitation and hazard control in each facility that produces seafood products for H.
I. S. This manual is also available on request from H. I. S. on diskette formatted to MS Word for Windows 95, 98 or 2000. This manual clearly explains the requirements all suppliers must meet and includes actual examples of the documents and records currently in use by Our U. S. D. C. and IJ. S. F. D. A. inspected facilities worldwide. We require that all suppliers meet the minimum requirements as stated in this manual. For this purpose, the word «shall» is used to indicate mandatory requirements and the word «should» is used to indicate suggestions from H. I. S.
In addition to the requirements set forth in this manual all suppliers shall: • Meet or exceed all local Federal, Provincial and lor State health and safety co sdiction where their facility is physically lo jurisdiction where their facility is physically located. • ge fully aware of and abide by Good Manufacturing practice for all production operations. • Never under any circumstances export any product produced outside ofthe guidelines contained in this Manual to H. I. S. without full notice in writing to H. I. S. and the express written permission of H. I. S. ?? Produce product only with full regard to environmental, ethical and occupational safety concerns. • Be prepared and available for unannounced audit visits by authorized H. I. S. representatives. Including, but not limited to, maintaining copies of all required documents and records in readily accessible form at the actual plant site or sites where H. I. S. products are produced. • Maintain at least one copy of this manual, in good condition, at the actual plant site or sites where H. I. S. products are produced. Page 3 EXAMPLE III-A Personal Hygiene Code 1 .
All personnel entering the receiving or processlng areas shall wear the approved protective uniforma The processing area uniform shall consist of rubber boots, white smock and White hair-net cap, white air net beard snood and mustache snood if applicable. 2. Protective clothing shall be worn only immediately prior to entering or while working in the area designated for its use. Protective clothing shall not be worn outside the area designated for its use, especially in the eating/ smoking area, outside the facility or in the bath rooms.
Protective clothing shall be turned in at the end of each work shift for in-hou 40F Protective rubber boots sh rn outside outside the facility. 3. Personnel hair and facial hair shall be fully enclosed vvlthin the hair-net cap or facial hair snood while in the processing area. 4. No jewelry shall be worn in the processing area. 5. No perfume or body scent shall be worn by processing personnel. 6. Fingernails shall be kept short, neat and clean. 7. All wounds cuts, sores, infections or abrasions shall be reported to the office and covered with disposable sanitary bandage material. 8.
All personnel must thoroughly wash their hands and rinse them with chlorine dip (water chlorinated to 50 PPM) or other H. I. S. -approved sanitizer each time they enter a food-contact area. g. Smoking and eating shall only be allowed in the designated rest area. 10. Any personnel suffering from infectious disease, ncluding flu, stomach complaints or food poisoning shall report to the office for evaluation prior to returning to work 11. No glass in food-contact areas. IV. Sanitation Standard Operating Procedure Each H. I. S. supplier shall write and maintain a plan for Sanitation for each facility that produces seafood products for H.
I. S. As required by both U. S. F. D. A. and the E. E. C. this plan shall be titled «Sanitation Standard Operating procedure» (SSOP). The SSOP, at a minimum, shall cover the following sanitation concerns: • Pest Control • Facility Structure and Lay s OF • Facilitv Maintenance ?? Ventilation • Waste Disposal • Measuring Equipment Calibration • Glass Status These concerns shall be addressed in detail in writing in vvritten form in the SSOP and checked daily using an SSOP Checklist that covers these concerns as written in the SSOP. This SSOP and SSOP Checklist shall be verified and audited by an authorized H.
I. S. technician. A written copy of the SSOP and all related records shall be kept in readily accessible form at the actual plant site or sites where H. I. S. products are produced. please see examples IV-A and IV-B on the pages following Photographs 2 and 3. This is an actual SSOP and SSOP Checklist currently in use in a IJSFDA and IJSDC inspected facility that supplies both fresh and frozen products to H. I. S. PHOTO Ali water and ice used throughout each phase of product handling shall meet World Health Organization Standards for Potable Water. PHOTO # 3.
Sanitation standards must be maintained throughout each Step of production, from harvest vessel to final packing and cold storage. EXAMPLE IV-A Sanitation Standard Operating Procedure 1. Sanitation Concern: Pests 1. 1 Elmlnate harborage and attractant areas for pests. • Method: Designated management and/or processing ersonnel shall keep weeds cut, pick up litter on facility grounds and keep harborage areas for pests free of 6 OF and/or processing personnel shall eliminate standing pools of water on facility grounds through drainage or manually on a dally basis as allowed by weather.
The above methods shall be listed on the Sanitation Checklist and checked daily for satisfactor,’ status by the designated management and/or processing 1. 2 Extermination of Pests • Method: An insect electrocution device shall be installed at the entrance ofthe processing plant within the first entry door and shall be properly aintained. • Method: Traps or poison bait shall be set out and checked on a daily basis by designated management and/or processing personnel or as needed and recom mended by a licensed pest control company to help control rodents. ?? Method: All non-product-contact areas and surfaces shall be treated with a non-persistent insecticide weekly to eliminate insect pests. All product-contact equipment and surfaces shall be covered or isolated during insecticide application. Alternatively, this shall be contracted to a licensed pest control company. he above methods shall be listed on the Sanitation Checklist and checked daily for satisfactory status by designated management and/or processing personnel. 2.
Sanitation Concern: Structure and Layout of Processing Plant 2. 1 Plant shall be in such a condition so as to prevent filth contamination from entering plant. (i. e. tracked in mud, airborne dust etc. ) • Method: Management shall ensure that the processing plant is cleaned and sanitized on a twice-daily basis by designated mana processlng shall be listed on the Sanitation Checklist and shall be checked daily for satisfactory status by designated management and/or processing 2.
The design, layout and materials used in the processing plant and employee rest rooms shall be able to be readily cleaned and sanitized to preclude contamination. • Method: Rooms shall be laid out and processing furniture placed so that they can be readily cleaned and sanitized at least twice daily. Page 5 • Method: Walls and floors shall be waterproofed and washable so as to be easily cleaned and sanitized daily. Checklist and checked daily for satisfactor,’ status by 2. Equipment and utensils shall be designed and located in such a way as to facilitate daily cleaning and sanitation by designated management and/or rocessing personnel. 3 Maintenance. The general condition of the facility shall be maintained to prevent the introduction of hazards. • Method: The general condition ofthe facility shall be checked on a weekly basis bythe plant manager or the designated assistant manager, who Will check for such things as peeling Paint, roof leaks, loose wiring, unsecured Wall panels and the like.
Repairs and upkeep shall be ongoing and of a preventative nature. • Method: Lights shall be covered to prevent physical contamination of the product. • Method: Equipment shall d and kept in good working order. Scale cked against Cooler refrigerators shall be monitored for proper cooling temperatures. • The above methods shall be listed on the Sanitation Checklist or the Calibration Checklist and checked for satisfactory status on a daily basis by 3. 1 Sufficient lighting shall be provided to ensure product safety and integrity. . 2 Equipment and utensils shall be maintained properly and kept in good repair. 3. 3 Product contact surfaces shall be kept in good repair, and shall be constructed of stainless Steel or other non-porous, non-rusting material. 4. Sanitation Concern: Cleaning and Sanitizing 4. The facility and equipment shall be cleaned and • Method: All crew members shall hose down the equipment walls, floors and product contact surfaces of the processing area with clean water every day to remove loase debris.
A foaming detergent agent shall be used in conjunction with the wash down procedure. • All floors, walls, sinks, drains and tables shall be rinsed vvlth water chlorinated to 50 ppm. This water shall be left on all surfaces for 30 minutes prior to being rinsed offwith clean water. • Method: Walls, floors and equipment shall be thoroughly rinsed with clean water after 30 minute oaking process in order to rinse off all chemicals, to prevent chemical contamination of the product by cleaning agents and to sanitize all surfaces. ?? Method: Refrigerated storage areas shall be cleaned and sanitized every month in the manner described above, or more frequently as required. • Method; All other areas of the facility shall be regularly cleaned and kept free of litter and excess clutter by designated man or processlng and kept free oflitter and excess clutter by designated management and/or processing Checklist and checked daily for satisfactory status by designated management and/or processing ?? All requirements for chlorine levels shall be checked daily and results entered on the Chlorine Level Checklist. . 2 Chemical Contamination Prevention • Method: All chemicals shall be properly labeled and stored in the Chemlcal storage area and checked daily on the Sanitation Checklist. 5. Sanitation Concern: Personal Hygiene 5. 1 All employees shall maintain a high degree of personal cleanliness to prevent contamination of food product. • Method: Employees shall thoroughly wash their hands with detergent soap and chlorinated water prior to working in production, after each break and after using toilet facilities.
Hand washing stations must be maintained in good working order with soap and clean paper towels in both the toilet and processing areas. Signs shall be posted in the toilet and processing areas reminding employees of handwashing requirements. • Method: Employees shall remove insecure jewelry prior to fish handling. Clean clothing and waterproof boots Will be worn. • Method: Eating, drinking, spitting and smoking shall not be allowed in the processing area or any other area where processing equipment or materials are handled. • Method: Employees with ries that may reasonablv be a possible s mination to