GOOD MANUFACTURING PRACTICES (GMP) & HAZARD ANALYSIS AND CRITICAL CONTROL POINT

(HACCP) SYSTEM
INCEPTION REPORT
Prepared by: Evans Omodo A.-EGIF LLC
Prepared for: THE AECF, LLC – March 2023 .15
Table of Contents

Table of Contents
1. Introduction 2
1.1 scope of work 3
2. Methodology 3
2.1 HACCP Concept 3
2.2 HACCP Plan 3
2.3 Proposed Approach…………………………………………………………………………………………………………..4
3. Guidelines for applications of HACCP Principles…………………………………………………………………..4
3.1 Prerequisite Programs………………………………………………………………………………………………………4
3.2 Education and Training……………………………………………………………………………………………………..5
4. Expected Deliverables……………………………………………………………………………………………………………6
5. Work Plan……………………………………………………………………………………………………………………………..6
6. References…………………………………………………………………………………………………………………………….7
 1. INTRODUCTION AND BRIEF DESCRIPTION OF THE PROJECT
Food is the basic requirement for survival of human being. After civilization, the food is being
manufactured in a factory where the main challenge is to produce quality food products. The
activity of food manufactures are to procure raw materials from different sources, processed,
packaged and safely made available for the end users i.e. consumers. One of the responsibilities
of food manufacturer is to ensure safe food. This means that it is neither injurious to health nor
unfit for human consumption. Now a day, food quality and safety has become a key issue in
worldwide, public health agencies and governments of several countries look for more efficient
ways to monitor production as well as supply chains. The World Health Organization (WHO)
since its inception promoted food safety as unsafe food has great health and economic
consequences. The conventional approach to ensuring food quality and safety, totally depends
on inspection as well as testing of final products. Further, conventional method has proved to be
inadequate in controlling food-borne disease outbreaks. The manufacture of a good food
product is not sufficient but, it must be free from pathogens as well as harmful additives and
remain/ maintain quality and safety for a period till it is consumed. So, in order to ensure quality
and food safety programme various methods have to be employed within the food industry, and
which will vary considerably in accuracy and sophistication as per type of process, size and
nature of resources available. Since the international market has become demanding in terms of
quality, safety and delivery, installation of Hazard Analysis Critical Control Points (HACCP) in food
industry encourages a competitive environment to food supplies in national and international
market. The HACCP system is adopted as an important tool in overall control of food borne
diseases (FBDs). The International Commission on Microbiological Specifications for Foods
(ICMSF), WHO, the Codex Alimentarius, and food regulatory agencies (KEBS) in various countries
are recommending the implementation of HACCP system. The keyword of the system is
“prevention” (Mortimore and Wallace, 1998), by means of the identification of possible
contaminations before they occur, and of the definition of control measures to ensure and
maximize food safety in each step of the process (Cullor, 1997). HACCP system, identifies,
evaluates, and controls hazards that are prominent for food safety. It can be applicable
throughout the food chain from the initial production to final consumption. It not only enhances
food safety but also better use of resources and timely response to problems. Due to that,
HACCP system is now widely accepted by the food industries as well as government regulatory
agencies around the world as a most cost-effective means of maximum reduction and
occurrence of identifiable food borne hazards i.e. biological, chemical and physical hazards and
maximizing product safety. Further, this system targets areas of processing and ultimately,
reduces the risk of manufacturing and selling unsafe products. The primary objective of a
HACCP programme is to provide reliable safe food among consumers. Industry is fairly familiar
with various microbiological, chemical or physical hazards and trying to control different types
of common hazards. In spite of, familiarity and knowledge of food poisoning derived from
microbiological and chemical causes, or injury from glass, wire and other hazardous physical
objects followed by their control is tedious and occasionally, they induce serious consumer
safety exposures and expensive product recalls and retrievals. It is therefore necessary to have
technical orientation on common microbiological, chemical, and physical hazards that may
cause serious problems in food.
1.1 SCOPE OF SERVICES
The EGIF LLC Consultants will support AECF with technical knowledge and expertise that
facilitates the implementation of the Good Manufacturing Practices (GMPs) and Hazard Analysis
Critical Control Point (HACCP) systems in the supported projects. Further they will visit,
including two (2) bakeries and one (1) restaurant to undertake the assignment. The exhaustive
list of the other details will be provided by KKCF.
2. METHODOLOGY
HACCP is a tool to assess hazards and establish control systems that focus on prevention
rather than relying mainly on end-product testing. Any HACCP system is capable of
accommodating change, such as advances in equipment design, processing procedures or
technological developments.
2.1 HACCP Concept
With the HACCP concept, a company checks the entire production process for possible
hazards to food safety. For each product, all phases of the production process, from raw
material to consumption, are systematically subjected to critical examination. The potential
hazards are identified. It is then necessary to specify how the risks associated with these
hazards are to be controlled.
2.2 HACCP Plan

 Assemble the HACCP team

 Describe the product

 Identify intended use

 Construct a flow diagram

 On-site confirmation of flow diagram

 Conduct a Hazard Analysis (Principle 1)

 Determine Critical Control Points (CCP) (Principle 2)

 Establish critical limits for each CCP (Principle 3)

 Establish a monitoring system for each CCP (Principle 4)

 Establish corrective actions (Principle 5)

 Establish verification procedures (Principle 6)

 Establish documentation and record keeping (Principle 7)

2.3 Proposed Approach

For successful implementation of a HACCP plan, management must be strongly committed
to the HACCP concept. A firm commitment to HACCP by top management provides company
employees with a sense of the importance of producing safe food.
Prerequisite programs such as current Good Manufacturing Practices (GMPs) are an
essential foundation for the development and implementation of successful HACCP plans.
Food safety systems based on the HACCP principles have been successfully applied in food
processing plants, retail food stores, and food service operations. The seven principles of
HACCP have been universally accepted by government agencies, trade associations and the
food industry around the world.

3. Guidelines for applications of HACCP Principles

The following guidelines will facilitate the development and implementation of effective
HACCP plans.
3.1 Prerequisite Programs
Facilities: The establishment should be located, constructed and maintained according to
sanitary design principles. There should be linear product flow and traffic control to
minimize cross-contamination from raw to cooked materials.
Supplier Control: Each facility should assure that its suppliers have in place effective GMP
and food safety programs. These may be the subject of continuing supplier guarantee and
supplier HACCP system verification.
Specifications: There should be written specifications for all ingredients, products, and
packaging materials.
Production Equipment: All equipment should be constructed and installed according to
sanitary design principles. Preventive maintenance and calibration schedules should be
established and documented.
Cleaning and Sanitation: All procedures for cleaning and sanitation of the equipment and
the facility should be written and followed. A master sanitation schedule should be in place.
Personal Hygiene: All employees and other persons who enter the manufacturing plant
should follow the requirements for personal hygiene.
Training: All employees should receive documented training in personal hygiene, GMP,
cleaning and sanitation procedures, personal safety, and their role in the HACCP program.
Chemical Control: Documented procedures must be in place to assure the segregation and
proper use of non-food chemicals in the plant. These include cleaning chemicals, fumigants,
and pesticides or baits used in or around the plant.
Receiving, Storage and Shipping: All raw materials and products should be stored under
sanitary conditions and the proper environmental conditions such as temperature and
humidity to assure their safety and wholesomeness.
Traceability and Recall: All raw materials and products should be lot-coded and a recall
system in place so that rapid and complete traces and recalls can be done when a product
retrieval is necessary.
Pest Control: Effective pest control programs should be in place.
Other examples of prerequisite programs might include quality assurance procedures;
standard operating procedures for sanitation, processes, product formulations and recipes;
glass control; procedures for receiving, storage and shipping; labeling; and employee food
and ingredient handling practices.

3.2 Education and Training

The success of a HACCP system depends on educating and training management and
employees in the importance of their role in producing safe foods. This should also include
information the control of foodborne hazards related to all stages of the food chain. It is
important to recognize that employees must first understand what HACCP is and then learn
the skills necessary to make it function properly. Specific training activities should include
working instructions and procedures that outline the tasks of employees monitoring each
CCP.
Management must provide adequate time for thorough education and training. Personnel
must be given the materials and equipment necessary to perform these tasks. Effective
training is an important prerequisite to successful implementation of a HACCP plan.
4 EXPECTED DELIVERABLES
1. Initial assessment report of each selected facility, indicating current practices, the needs
and
requirements for effective GMP/HACCP implementation (Gap Analysis) for three investees
namely Steve Kings Bakery, Nice Bakery and Neema Hotel under the KKCF Program.
2. Provide guidance on methodology for hazard identification and formulate guidelines on
how to identify common and relevant hazards categorizing the various types whether they
are biological, chemical, physical or allergens. Also design a hazard ranking matrix and rank
the hazards identified in the establishments.
3. Design the requisite critical control programme/ activities for hazard control with
considerations on critical limits and monitoring system, and to show application in each of
the businesses
4. Identify some of the challenges that businesses may encounter in implementing the
critical control programme for the hazards and recommend appropriate solutions.
5. Build the capacity of management and staff in the business establishments in applying the
developed critical control programmes for hazard control and monitoring system
6. Technical knowledge transfer to KKCF officers on application, monitoring and reporting on
HACCP/GMP

5 WORK PLAN (ATTACHED)

6. REFERENCES
DWAF 2007. Lower Usutu River - Government Water Scheme. Temporary Rehabilitation
Measures – Design Report.
Internal Report Prepared by the Directorate: Civil Engineering of the Department of Water
Affairs and Forestry of South Africa. August 2007.
Antle, J.M. (1998) The cost of quality in the meat industry: Implications for HACCP regulation.
Paper presented at the NE-165 Conference on Economics of HACCP, June 15-16, 1998,
Washington D.C.
Besanko, D. (1987) Performance versus design standards in the regulation of pollution. Journal
of Public Economics 34. 19-44.
Buzby, J.C., Roberts, T., Lin, C.-T.J., and MacDonald, J.M. (1996) Bacterial foodborne disease:
Medical costs and productivity losses. Economic Research Service, U. S. Department of
Agriculture, Agricultural Economic Report No. 741.