2007 PLACE Conference

September 16-20

St Louis, MO

HACCPHave You Checked Your Hazard

Analysis Lately?

Presented by:Suzanne MatuszewskiManager, Product SafetySonoco

•Headquartered in Hartsville, SC•Founded in 1899•More than 300 operations•36 countries/5 continents•17,000 employees•Sales $3.7bn

Consumer

Flexible Packaging

Global Composite Cans Plastic Containers

Metal EndsProtective Packaging

Industrial

Tubes and Cores Paper

Molded Plastics

Other

Services

Service Centers, Graphics Management and P-O-P Displays

Business Segments

HACCP’s PURPOSEIncreased assurance for consumers of packaged foods receive packages free from defects that may cause food safety issues.

• Consumers expect and need a safe food supply

• Food packaging in contact with food needs to follow the same food safety requirements as the food itself

• Hazard/ Risk Analyses are beneficial for everyone…. Think about safety, environmental, and insurance liabilities

• Hazard / Risk Analyses are currently “required” in some instances – Canada’s “Challenge” program, Europe’s REACH program i.e.

It just makes good business sense!!!!!

HACCP Overview

• Conceptualized by Pillsbury in 1960’s to develop foods for the space program

• Based on FMEA “Failure, Mode, and Effect Analysis” …. What if…

• Trend towards prevention and validation of raw materials and processes

Seven Principles

1. Hazard Analysis : not just a flow chart2. Determine CCP3. Establish critical limits4. Monitor CCP5. Corrective action6. Verification7. Documentation / Record Keeping

Focus for Packaging Suppliers

• CHEMICAL HAZARDS:− Prevention of cross contamination : food grade v. non− Controls in place to assure processing chemicals are approved for specific use

• PHYSICAL HAZARDS:− Prevention of metal, glass, plastic, wood, etc.

• MICROBIOLOGICAL HAZARDS:− Prevention of contamination or potential for growth of pathogens

When HACCP fails…..

2006 FDA Food Recalls source: Silliker June 22, 2007 Food Safety and Science News

Source:Silliker

AllergensMicrobiologicalProcess ErrorsMislabeledSulfitesExtr. MaterialColorPestsOther

CategoryOther2.4%

Pests1.0%

Color5.9%

Extr. Material5.9%

Sulfites6.7%

Mislabeled7.2%

Process Errors17.6% Microbiological

25.4%

Allergens27.8%

Current Status of Food Safety Programs for Suppliers – Real World

• Suppliers need to look at their material as food contact

• Hazard analysis / Risk analysis needs to be performed based on risks to the consumer that will eat the packaged food (not based on the material only as produced).

• You already likely have many controls in place. Utilize your existing programs.

• Recognize that you are part of the food supply chain. Think about what the customer needs.

Suggestion of a Risk Assessment

Severity x Likelihood = RISK

Severity : How serious could be the outcome?

Likelihood : Has it happened or can it foreseeably happen?

SCALE1= not very likely/ not hazardous2=somewhat3=could cause a food safety issue

Levels of ActionR = 1- 3• Low level risk – Establish quality or other

pre-requisite programs if appropriate

R= 4-6• Medium level – Use quality or pre-requisite

control measures

R=7-9• Potential Critical Control Point

SAMPLE Hazard Analysis

Hazard Analysis

Process Step 10

Hazard

Type

L

S

R CCP

Control Measures

Documentation

Raw material not approved

F 1 3 3 No Ensure that all raw material is purchased approved for 'direct food contact' and the supplier provides all relevant specifications and certification

Change control approval and procedure

Generic contamination caused by poor handling and controls at suppliers

F 1 2 2 No Only purchase raw material from approved suppliers who can demonstrate the required level of product safety.

Selection and assessment of raw material suppliers

Receipt of raw materials

Contaminated deliveries

F,C 1 3 3 No Inspect all raw material for damage to original packaging; inspection of trailers upon arrival in the plant

Receipt of material procedure (incoming vehicle and load inspection)

Process Step 20

Hazard

Type

L

S

R CCP

Control Measures

Documentation

Storage of raw materials

Generic contamination caused by poor handling

F 1 2 2 No Ensure that all raw material remains in original packaging until issued to production. Ensure that the cleaning schedule is applied and external doors are kept closed when not in use

Master sanitation schedule; assignment to Shipping Dept.

GM

P T

raining procedure, PSA

audit procedure

Possibilities for non-HACCP Control Points/Programs

• ISO• Quality System• Vendor• Customer• GMP• Others ????.... think out of the box…..

How to get started….

• Understand the need for a HACCP/Food Safety Program–commitment to the food supply

• HACCP based Hazard/Risk assessment performed from the perspective of hazards and risks associated with the finished food package as to be consumed

• Hazards may be controlled by Prerequisite programs (nomenclature may be different e.g. QCP) based on your system and the knowledge of your product’s use.

• Effective controls must be in place NOW even if food safety risks are not identified– even if formal HACCP program is not in place

Summary• Food Safety Programs are new to many

suppliers

• HACCP would provide a structured approach to risk assessment and is well established in the food industry

• Be creative and find solutions that fit your operations. There is no “one size fits all” when it comes to ensuring food safety.

• Your product could be in your child’s lunchbox next week.

HACCP programs at material manufacturers and packaging

suppliers work jointly to keep our food supply safe for the consumer

FOOD SAFETY IS NOT NEGOTIABLE

Thank YouPRESENTED BY

Suzanne MatuszewskiManager, Product Safety

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