HACCP A Plan For Food Safety Training Video & DVD by Coastal Training / DuPont

HACCP A Plan For Food Safety Training DVD
 
  • SKU: HAC001-DVD
  • Copyright: 2010
  • Runtime: 22 mins
  • Producer: Coastal Training / DuPont
What's in The Box
  • (1) 22 Minute Training DVD
  • Training Points and Bonus Material (printable download)
  • Resourceful Web Links (printable download)
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Coastal's HACCP A Plan For Food Safety DVD

According to the CDC, an estimated 76 million cases of foodborne disease are reported each year in the United States. The CDC also estimates that there are 325,000 hospitalizations and 5,000 deaths related to foodborne diseases each year. Don't let your facility become the reason for a foodborne illness outbreak. HACCP: A Plan For Food Safety looks at why having a Hazard Analysis and Critical Control Points (HACCP) plan in place is a necessity to protect consumers from disease and your organization from negative publicity.

This program will help your employees understand why it is critical to follow the plan because one decision to bypass safety could cause serious illness or even death.

             Foodborne Illness

  • Foodborne illness, or food poisoning, is caused when someone eats or drinks contaminated or improperly handled food or beverages.
  • Outbreaks of foodborne illness can occur when people become ill from eating a contaminated meal together or when different people buy the same contaminated item from a grocery store or restaurant.

    Introduction to HACCP
  • HACCP is Hazard Analysis and Critical Control Points Principles that focus attention on food safety at every step of the journey from the farm to the consumer's table.
  • Every supplier, manufacturer, processor, distributor, food service organization and retail food store should have its own HACCP plan specific to its product and operations.

    Create a successful HACCP plan
  • Get commitment from management.
  • Put prerequisite programs in place.
  • Have a system in place for educating and training employees.
  • Perform the five preliminary tasks before developing a HACCP plan.
  • After these five tasks have been completed, apply the seven principles of HACCP.


Added features and benefits of this HACCP A Plan For Food Safety DVD include:

  • English and Spanish versions
  • Informative training points and bonus material for refresher or training sessions
  • Video-enriched training organized around learning objectives to facilitate discussion
  • Resourceful web links to organizations such as OSHA, FEMA, NSC and the CDC, where viewers can download and print information on regulatory standards
  • Format: DVD
  • Language: English, Spanish, or Portuguese
  • Length: 22 minutes
What's in The Box

What's In The Box

  • (1) 22 Minute Training DVD
  • Training Points and Bonus Material (printable download)
  • Resourceful Web Links (printable download)
Preview

Video Transcript

What do spinach, frozen pies, cookie dough, ground beef and peanut butter have in common, they were all identified as sources of foodborne illness outbreaks in recent years. Foodborne illness is more small matter, government figure shows that one in four americans suffer from food borne over year. Over 300,000 people would be admitted to the hospital and 5,000 people will die from an illness, that's about 13 men, women and children everyday.

The cause of foodborne illness are gray, beyond the negative health effects of an outbreak, there are cause brought on by lawsuits, negative media coverage, higher insurance premiums and decreased morale, this cause could potentially put an organization at financial risks. So how do we confide borne illnesses from happening by creating an effective food safety program using hazard analysis and critical control point principles or HACCP and by carefully following all food safety handling procedures. Every single person who works with food needs to take responsibility for his or her part in the process not just because it's in the job description but because mothers and fathers, grandparents, brothers and sisters, infants and toddlers, friends and neighbors are all counting on you if you keep their food safe.

Foodborne Ilness
Foodborne illness or food poisoning is cause from someone who eats or drinks contaminated or improperly handled food or beverages. Outbreaks of foodborne illness can occur when people become ill from eating that contaminated meals or when different people by the same contaminated item from a grocery store or restaurant. Food doesn't have to taste or smell bad when it is unsafe, in fact the food often looks fresh and taste fine so people eat it not knowing it's unsafe. After the food is eaten it takes a few minutes to a few days for symptoms to appear, 250 different foodborne illnesses have been identified which means a lot of different symptoms are possible. However, many foodborne illnesses commonly cause nausea, abdominal cramps and diarrhea.

Most foodborne illness is caused by poor or improper food handling procedures. Often foodborne illnesses are infection cause by bacteria, viruses or parasites. The most common bacteria that cause illness are campylobacter, salmonella and E. Coli. Keep in my thought that contaminants can include other things such as toxins, chemical poisons, pesticides and even visible objects such as glass, metal, bone or rocks. Widespread outbreaks of foodborne illness usually get a great deal of news coverage but a large majority of the reported cases of foodborne illness are individual cases that are not part of a recognize outbreak, and according to the Center for Disease Control and Prevention (CDC) most cases of foodborne illness are not reported at all because the ill person doesn't see a doctor or the doctor doesn't make a specific diagnosis. When it comes to your workplace, you won't know a food is contaminated until an outbreak is trace back to your facility. For this reason, your facility should have hazard food safety plan, so you can prevent foodborne illness in the first place.

Introduction to HACCP
Because of the high cost of a foodborne illness outbreak, your consumers health and to your organization's livelihood your facility should have a plan that addresses hazard analysis and critical control point principle or HACCP. HACCP was created that focus attention on food safety and every step of the journey, from the farm to the consumer's table. The main goal of HACCP is to prevent foodborne illness rather than to fix problems after they occur. In your workplace, haccp involves examining every part of the food handling process step by step to figure out possible biological, chemical or physical hazards that exist and the dust waste to control it. Every supplier, manufacturer, processor, distributor, food service organizations and retail food stores should have its own hazard plan specific from its product and operations. There are many bases having a hazard program in your workplace which includes; 

  • complying with food safety regulations
  • preventing foodborne illness
  • using resources more effectively
  • and being able to respond quickly to problems if they occur

In the next few minutes, we'll discuss hazard in more details so you can understand why having and following your facility's hazard plan  is so important.

Setting the Stage for HACCP
In order to create a successful hazard plan for your workplace several things must be in place. First, you must have commitment from management that food safety is a top priority. Next, certain programs must already be in place to support having a hazard plan. These programs are known as prerequisite programs, they provide the basic operating conditions that are required for the production of safe food products. Many of these programs are already required by federal state and local regulations or guidelines. Some examples of prerequisite programs include the construction and maintenance of facilities, according to sanitary design principles, written specifications for all ingredients, products and packaging materials, the proper storage of raw materials and products, procedures for sanitation and cleaning, requirements for personal hygiene and pests control programs. All prerequisite programs should be documented and reviewed  regularly.

In order to have a successful hazard program, your facility must also have a system in place for educating and training employees, your food safety program can be successful and personnel are adequately trained on their responsibilities. Before developing a hazard plan your workplace should perform five preliminary tasks. 

  1. The first tasks is to assemble a HACCP team - the team should include people who have specific knowledge and expertise of the product and process as well as local employees who are involve in day to day operations.
  2. Describe the food and its distribution - a general description of the food, ingredients and processing methods should be completed. The method of distribution should also be described including information about whether the food is to be distributed frozen, refrigerated or at ambient temperature.
  3. Intended use and consumers of the food - examples of intended use includes to be eaten raw or lightly cooked or to be fully cooked before consuming. Some examples of the intended consumers are the general public, infants or the elderly.
  4. Develop a flow diagram to show each step in the food handling process at your facility. Don't forget to include the receiving and shipping of food products to and from your workplace.
  5. Verify the flow diagram - it should be done by an on site review of the operation, make sure the flow diagram is accurate and complete.

After these five tasks have been completed, you can begin applying the seven principles of HACCP.

Principles of HACCP
The seven principles of HACCP are basically the steps the HACCP's team needs to take to create an effective hazard program. The seven steps are:

  1. Conduct a Hazard Analysis
  2. Determine Critical Control Points
  3. Establish Critical Limit
  4. Establish Monitoring Procedures
  5. Establish Corrective Actions
  6. Establish Verification Procedures
  7. Establish Record keeping & Documentation Procedures 

A detailed hazard analysis is a vital part of a hazard plan. If the hazard analysis is not done correctly and hazards are not all identified, the HACCP plan will not be effective no matter how well employees follow it. There are two stages in a hazard analysis in a first stage, the HACCP team develop a list of potential hazards that are reasonable likely to cause injuries or illness if not properly controlled. Hazards can be biological such as bacteria, viruses or parasites, chemicals such as cleaners, sanitizers or pesticide, or physical such as metal filings, bone fragments, bandages or finger nails. When doing the hazard analysis the team should consider ingredients and raw materials the activities perform in each step of the food operations, products storage and distribution as well as the final preparation and use by the consumer. 

The second stage of hazard analysis is evaluating each of the hazard that were identified. The goal of this stage is to figure out which potential hazards must be address in a hazard plan. To determine this each potential hazard is look at in terms of how severe or serious the result would be if someone were exposed to the hazard and how likely it is for exp osure to occur. Let's take the examples of an organization that uses raw ground pork in its operations. The HACCP team lists that E.coli O157 H7 and salmonella bacteria are hazards of using raw pork in food operations. Scientific evidence and past experience shows that these bacteria can cause severe health effects including death among children and the elderly. How likely is this exposure to occur? The team finds that the likelihood of E.coli being in the news is very low and the likelihood of salmonella being present is moderate. 

After evaluating these information the team decides that the hazards must be address in a HACCP plan. To complete the hazard analysis all hazards should be listed all measures that should be use to control the hazard. For example, the hazardous bacteria in raw ground pork can be controlled by proper cooking. The second hazard principle is to determine critical control points. Critical control points or CCPs are the steps in the food handling process that must be controlled in order to prevent, eliminate or reduce hazards to an acceptable level. Identifying these CCPs is essential to food safety. Example of CCPs may include heating, refrigerating, disinfecting surfaces, approving suppliers, handwashing, avoiding bare hand contact with ready to eat foods, ensuring sick employees are not handling foods, setting room temperature and sealing of packaging. CCPs identified in your facility must be documented in your HACCP plan.

The third principle is to establish critical limits or each critical control point. A critical limit is a maximum or minimum value that must be maintain to control the identified hazard. Critical limits are based on factors such as temperature, time, humidity, water activity, pH, salt concentration and preservatives. Critical limits must be based on scientific fact and may be found in regulatory standards and guidelines and information from experts among other sources. Examples of critical limits could include storing food at or below 41°F and cooking ground pork to a minimum internal temperature of 155°F for 22 seconds or more. The next step in developing a HACCP plan is to establish monitoring procedures to make sure critical limits are being met. Monitoring should be an organize process where observations or measurements are planned, performed and then recorded, the goal is to make sure that critical control points are under control. Ideally monitoring should continuous but it's not always practical.

When deciding how long the time will between monitoring, the HACCP team should remember that if a critical limit measurement does not need specifications, then all of the product from the last acceptable measurement must be examined for safety. Monitoring procedures should be easy to follow and they should clearly note who is in charge of monitoring each critical control points. If you will be monitoring CCPs you should be trained in proper monitoring techniques always keep in mind how important monitoring is to food safety. If the process or product doesn't need critical limits you should follow your facility's guideline for reporting and handling the situation. When performing monitoring procedures always date and initial the measurement you've recorded, monitoring equipment should also be routinely tested to make sure it's accurate.

Every HACCP plan should establish corrective actions for each critical control points in case critical limits are not met. For instance, if internal temperature of this cheesecake is found to be below 160°F then corrective action needs to be taken. In this instance, the corrective action could be cooking the cheesecake longer. Other examples of corrective actions includes repairing a refrigerator, so that it maintain proper temperatures and rejecting a food product from a supplier that doesn't meet you facility's specifications. When taking corrective actions follow these four steps;

  1. Determine what the problem is and correct it.
  2. The safety of food product must be determine, you or your supervisor will have to figure out whether the product can still be used if not it must be destroy.
  3. Record all corrective actions that were taken including the date and time.
  4. Determine a way to prevent this type of incident from happening again.

The bottom line when it comes to corrective actions is that you want to prevent hazardous food from reaching consumers.

The next step in creating an effective HACCP plan is to establish verification  procedures. The goal of this step is to make sure that the HACCP program is working the way it is suppose to work. first, the whole HACCP plan should be check before it goes into effect, to make sure it is scientifically accurate the plan should then be updated whenever there are significant changes to the system such as changes in equipment, processes or critical limits. The HACCP team should also make sure that monitoring is taken place according to the plan, this process should include a HACCP team member directly observing monitoring to make sure it is being done correctly. Monitoring equipment should be check regularly to ensure that it is working properly. The team should also establish procedures that make sure records of monitoring and corrective actions are being kept.
 
Proper recordkeeping is important part of the HACCP plan for several reasons. Accurate records allow facilities to recognize trends in production line, document compliance with food safety regulations and ultimately protect the consumers of your product. Accurate records also help trace ingredients or finished products in case problem occurs. The two types of records the HACCP team needs to address are the overall plan records and day to day records.
Overall Plan Records - include things like a listing of HACCP team members, a description of the food, its distribution, intended use and consumer, the flow diagram that was created, the hazard analysis, including any documents or data used to support decisions made in the hazard analysis, critical limits, monitoring procedures and corrective actions to be taken.
Day to Day Records - include thins like monitoring records and corrective action logs.
By following the seven HACCP principles your facility can create an effective plan from maintaining food safety. When you and your co-workers follow the guidelines under this plan, you'll ensure the safety of consumers who rely on you to protect them from foodborne illness.
 
Reportable Food Registry
In order to help food manufacturers and processors focus on food safety and prevention, the Food and Drug Administration(FDA) has created a reportable food registry or RFR, this electronic registry goes hand and hand with the regulation that requires facilities that manufacture, process, pack or hold food for consumption in the U.S. or report to the FDA within 24 hours if they believe there is a reasonable probability that the food item will cause severe health problems to a person or an animal. Examples of one of food product maybe reportable include bacterial contamination, mislabeling of allergens or the presence of certain chemicals at high levels. Once a company or organization reports the food item through the registry, it is then required to work with the FDA to determine the cause of the health risk and help prevent any public health problem.
 
The registry applies to all FDA regulated categories of food and animal feed, except dietary supplements and infant formula which are subject to other regulations. One major benefit of the registry and the 24 hours deadline to report is that the food product can be track down and the public alerted more quickly than when reporting was only voluntary. The registry also helps the FDA track patterns and target inspections. If your facility handles any food products other than dietary supplements or infant formula, remember that you must report an unsafe food item to the registry within 24 hours.
 
Food Safety During Transport
Everyday millions of food items move between farms, processors, distributors, food service operations and retail sellers. Because food products can spend a good deal of time in transport, it's important for every organization that transport foods to have a thorough HACCP plan in place. This plan should cover several areas of special concerns and transport operations including;
  • avoiding avoiding temperature abuse
  • preventing cross-contamination and
  • defending food from tampering

Maintaining proper temperatures during loading, unloading and shipping is critical to food safety, this process is sometime known as "maintaining the cold chain". Keeping temperatures at proper levels is not easy as it might seem especially when you consider that mix loads of frozen, refrigerated and dry items can require different storage temperatures and transport vehicles can make delivery stops. To help avoid temperature abuse, check the cooling unit often to make sure it is working properly, use portable bulkheads when available to separate frozen, refrigerated and dry items, and make sure they sealed tightly. Pre-cool trailer before loading for the insulation and air can be chilled to the proper temperature. Lastly, avoid turning off refrigeration system to save fuel, since doing so could result in temperature falling below safe levels. 

Prevent Cross-Contamination
Cross-contamination during transport is another food safety concern. Always transport food products in appropriate vehicles that are not use to transport none food items that could make the food products unsafe. Inspect vehicles before loading to make sure there are no food or chemical residues in previous cargo. When loading make sure raw products are kept separate from finished products, if you pick up returned good from a site make sure this damage or rejected items are also kept apart from other food products so you don't accidentally deliver contaminated items. 
 
Defend Food From Tampering
Keeping our nation food supplies safe from terrorists acts is an important matter. You can help protect the food you transport using locks and seals on vehicles, sealing cases inside the vehicle with tampered evident materials. Never leaving a trailer open or unlock when you step away on it. Inspecting your vehicle and observing your work area from anything out of the ordinary and finally, reporting unusual no matter how minor to your supervisor right away.
 
Today you've learned about HACCP and how having a thorough food safety plan benefits consumers as well as your organization. Keep in mind that a HACCP plan is a living document that should be updated to keep up with improvements in science and foodborne illness control and to reflect any new an stronger disease producing agents that emerged. Seek out additional HACCP training or support but you need help to ensure that your plan enhances food safety and complies with regulations. Remember that having a plan is not enough, every employee must take a commitment to follow the plan. One decision to bypass the safety could cause serious illness or even death. Don't let that happen on your watch. Keep consumers safe from foodborne illness by doing your part everyday.
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