20 replies to this topic

[vinno01]

Hi All

Im new to Haccp. my business makes a product predominantly containing wheat and few other ingredients, and our biggest problem is insect infestation from weevils. I have completed the process flow step by step and I cant see any processing step which kills or reduces any weevils, eggs etc if present. we do have a goods inwards quality inspection, which can reject incoming Wheat if weevils/ eggs are identified, is this the CCP? Our supplier specifications also ask for insect free so maybe this is a ccp ? plus we also audit the suppliers aswell.

We also fumigate the site on a regular basis to kill off any insects present and also have insect baiting points in place throughout the factory. Im guessing that fumigation is not part of the manufacturing process but should be classed as a pre requisit programme instead, not a CCP?

i may of answered my own question but just need guidance from the Pro's. thanks


Vinno1

[GMO]

Hi All

Im new to Haccp. my business makes a product predominantly containing wheat and few other ingredients, and our biggest problem is insect infestation from weevils. I have completed the process flow step by step and I cant see any processing step which kills or reduces any weevils, eggs etc if present. we do have a goods inwards quality inspection, which can reject incoming Wheat if weevils/ eggs are identified, is this the CCP? Our supplier specifications also ask for insect free so maybe this is a ccp ? plus we also audit the suppliers aswell.

We also fumigate the site on a regular basis to kill off any insects present and also have insect baiting points in place throughout the factory. Im guessing that fumigation is not part of the manufacturing process but should be classed as a pre requisit programme instead, not a CCP?

i may of answered my own question but just need guidance from the Pro's. thanks


Vinno1

I've never worked in this kind of product. There are positives and negatives to some of your proposals for CCPs. Generally pest control issues would more normally be controlled by prerequisite. Are there any growth conditions with the wheat which might ensure the grower / wholesaler could ensure the wheat is weevil free? This again would point to supplier assurance being a prerequisite.

The best advice I can give though is for you to have some training. To be the HACCP team leader which I assume you are, ideally you should be trained up to RSPH Level 4 in HACCP or equivalent (or level 3 is probably ok), certainly I would recommend getting this training if there is no-one on site who has it. You can't just start with the Codex CCP flow diagram and assume you'll get a good HACCP plan out of it; that way you will end up with 20+ CCPs!

[vinno01]

I've never worked in this kind of product. There are positives and negatives to some of your proposals for CCPs. Generally pest control issues would more normally be controlled by prerequisite. Are there any growth conditions with the wheat which might ensure the grower / wholesaler could ensure the wheat is weevil free? This again would point to supplier assurance being a prerequisite.

The best advice I can give though is for you to have some training. To be the HACCP team leader which I assume you are, ideally you should be trained up to RSPH Level 4 in HACCP or equivalent (or level 3 is probably ok), certainly I would recommend getting this training if there is no-one on site who has it. You can't just start with the Codex CCP flow diagram and assume you'll get a good HACCP plan out of it; that way you will end up with 20+ CCPs!

[vinno01]

thanks for responding. im actually the purchasing manager drafted in to run the HACCP. I did a course many moons ago At Campden BRI and probably need a refresher to be honest. I have done HACCP before in chilled high care foods, prawns to be exact and ended up with 20 CCP's however I then discovered the decision tree which worked a treat. We actually compact/compress the wheat under extremes of pressure and Im running trials to discover if this is infact a kill process step.

Thanks for you help though.


Vinno.

[GMO]

thanks for responding. im actually the purchasing manager drafted in to run the HACCP. I did a course many moons ago At Campden BRI and probably need a refresher to be honest. I have done HACCP before in chilled high care foods, prawns to be exact and ended up with 20 CCP's however I then discovered the decision tree which worked a treat. We actually compact/compress the wheat under extremes of pressure and Im running trials to discover if this is infact a kill process step.

Thanks for you help though.


Vinno.

20 CCPs in high care would now be considered very high. I definitely encourage you to go on a refresher. What was the course you did? What level?

Don't be offended but I'm concerned that you "discovered the decision tree" as it's a fundamental part of HACCP training nowadays including discussions of it's limitations (it has the tendency to identify too many CCPs for example. Glass control and handwashing are classic misidentified CCPs if you follow the decision tree to the letter.) I think if you're going to be leading the HACCP team you need a bit more confidence in the subject which refresher training should provide.

Alternatively you'd be a great team member to have with the training you already have in place but perhaps if there isn't technical expertise at the right level, your company should be training your Technical person?

[vinno01]

20 CCPs in high care would now be considered very high. I definitely encourage you to go on a refresher. What was the course you did? What level?

Don't be offended but I'm concerned that you "discovered the decision tree" as it's a fundamental part of HACCP training nowadays including discussions of it's limitations (it has the tendency to identify too many CCPs for example. Glass control and handwashing are classic misidentified CCPs if you follow the decision tree to the letter.) I think if you're going to be leading the HACCP team you need a bit more confidence in the subject which refresher training should provide.

Alternatively you'd be a great team member to have with the training you already have in place but perhaps if there isn't technical expertise at the right level, your company should be training your Technical person?

[vinno01]

Hi, Yes did HACCP training in 1989 (cant remember level), there was no decision tree then, it came out after this. must be getting old , damn grey hair. Thats why i describe myself as new to haccp as im guessing it might of changed?? i worked in 'Technical roles for UB, Youngs chilled fish, Marr Frozen Foods, Dalgety Petfoods, Pataks Foods years ago.

i did my degree dissertation on HACCP and discovered that most companys were really struggling to implement it correctly at the time.

A refresher would certainly help, its great advice and Im getting myself on a course asap

Haccp is a great system and Im enjoying revisiting it even with my procurement hat on. why did I ever leave it.!

The business I work for now is a multinational, it likes to multiskill and challenge its professionals, Technical manager is contracting the wheat next quater!

[Charles.C]

Dear vinno,

As per GMO, it's unlikely to be a CCP unless (in some interpretations) the discovery step might be at yr material reception stage and the consequence of the weevil is a specific safety threat.

One removal suggestion is here -

http://pests.getrido...-of-weevils.htm
(personally I have always stored my wheatflour etc at -18degC after my first consignments at ambient temperature "walked' away after a few months. )

There are also several professional exterminators posting on this forum, eg a certain "Bunny" for one.

Rgds / Charles.C

[PaulbSW]

Ok everyone already talked about how it’s not a CCP so I will talk about the fumigation of your plant are you doing any testing during you are fumigating ,to ensure that you are getting kills throughout your facility? I understand what a pain weevils/insects can be coming from rice. I feel your pain!

[GMO]

There are plenty of subjects I've not revisited since 1989 but unfortunately HACCP has moved on a long way. Very few companies adopted it back then as you know and where they did, huge numbers of CCPs were common. Even though you are so well trained, it would probably be a good idea to do Level 4 CIEH again if your company is prepared to pay for it. There have been legislative changes in the last 20+ years as well as a change in approach brought about by more companies adopting it and the various standards which have picked it up.

[MQA]

Hi Vinno. My responses are in blue.

Im new to Haccp. my business makes a product predominantly containing wheat and few other ingredients, and our biggest problem is insect infestation from weevils. I have completed the process flow step by step and I cant see any processing step which kills or reduces any weevils, eggs etc if present.

• HACCP is about prevention. It's a proactive approach rather than a reactive approach.
  
• Ideally, all raw materials entering your premises should be pest free. Perhaps identify first where the infestation derives from? Is it from your Suppliers? Or is from your storage conditions?

we do have a goods inwards quality inspection, which can reject incoming Wheat if weevils/ eggs are identified, is this the CCP?

• It might help if you showed us your policy / instruction on Inwards Quality Inspection. Perhaps there are missing elements? If your wheat comes in pallets or major sealed containers, I am curious to know how your staff can identify infestation (outside of lost packaging integrity)? Weevil eggs are quite small.
• Looking for Physical Contamination (in this case, weevils) in the Receival of Raw Materials is generally just a CP. Your control points would be an Approved Supplier Program, Staff Training on Receival methods and acceptance, Cleaning & Sanitation of the receival dock.
  

Our supplier specifications also ask for insect free so maybe this is a ccp ? plus we also audit the suppliers as well.

• For wheat and other grains, your supplier should be providing you with a COA | Certificate of Analysis with every delivery
• How are your suppliers audited?
  

We also fumigate the site on a regular basis to kill off any insects present and also have insect baiting points in place throughout the factory. Im guessing that fumigation is not part of the manufacturing process but should be classed as a pre requisit programme instead, not a CCP?

• A Pest Control Management System should be by default with any company that has wheat and other such grains.
  
• Your Pest Control program should be conducted by professionals, ideally monthly if you are currently having insect issues.
• Your company's general housekeeping should also include a preventative measure for Pest Control
• Pest Control is not a CCP.
  

Hope this helps.

[YongYM]

Vinno:



How fresh is your wheat flour upon receiving? If I am not mistaken, weevils usually hatch 15 days after flour milling especially hot / humid condition and if the eggs are not properly destroyed (by the entoleter from the flour miller).



Do you sieve your flour before you use?


Yong

[Eya]

Vinno1,

Definetly not a CCP. It should be controlled by your three pre-requisite program namely: Supplier Assurance, GMP and Integrated Pest management program. I seen before a "insect destroyer" machine, which not only suck the adult weevils but also damaged their eggs to ensure no growth. For the fumigation, unless you have what they call as "proof of kill" then you cannot say its effective.

[MRios]

Like Yong YM said, you would need an entoleter to get rid of weevil eggs, but this is for flour. I suppose you make wheat flakes, since you speak of compressing the wheat. Do you have a separator? These have sieves that separate wheat from any foreign material that does not have the shape, size and density of wheat kernels. In many cases, it also takes care of infested kernels, since these are hollow most of the time.

What kind of weevils do you have? Tribolium are characteristic of flour products, Sitophilus are usually found in grain.

Make sure you check elevator heads and "feet", since there might be product or wheat accumulating at these points, or at any other spots that are difficult to reach (i.e. structures that are above eye level, cloth connectors in sifters or separators, felt lining). You might want to look into having some sort of security sifter.

Methyl bromide is extremely efficient at getting rid of these pests, but I suppose it´s not allowed in the UK. Or aluminum phosphide, which is also extremely poisonous, so of course, you would need a professional pest control company taking care of this, preferably one that has experience treating mills.

I seriously doubt that you´re getting weevils from your provider. Anyhow, take samples while the trucks are being unloaded and use a 1000 micron mesh to sift them. It´ll be easy to see if your raw material is infested or not.

[vinno01]

Dear vinno,

As per GMO, it's unlikely to be a CCP unless (in some interpretations) the discovery step might be at yr material reception stage and the consequence of the weevil is a specific safety threat.

One removal suggestion is here -

http://pests.getrido...-of-weevils.htm
(personally I have always stored my wheatflour etc at -18degC after my first consignments at ambient temperature "walked' away after a few months. )

There are also several professional exterminators posting on this forum, eg a certain "Bunny" for one.

Rgds / Charles.C

[vinno01]

thats great thanks.

[vinno01]

Hi Vinno. My responses are in blue.

Im new to Haccp. my business makes a product predominantly containing wheat and few other ingredients, and our biggest problem is insect infestation from weevils. I have completed the process flow step by step and I cant see any processing step which kills or reduces any weevils, eggs etc if present.

• HACCP is about prevention. It's a proactive approach rather than a reactive approach.
  
• Ideally, all raw materials entering your premises should be pest free. Perhaps identify first where the infestation derives from? Is it from your Suppliers? Or is from your storage conditions?

we do have a goods inwards quality inspection, which can reject incoming Wheat if weevils/ eggs are identified, is this the CCP?

• It might help if you showed us your policy / instruction on Inwards Quality Inspection. Perhaps there are missing elements? If your wheat comes in pallets or major sealed containers, I am curious to know how your staff can identify infestation (outside of lost packaging integrity)? Weevil eggs are quite small.
• Looking for Physical Contamination (in this case, weevils) in the Receival of Raw Materials is generally just a CP. Your control points would be an Approved Supplier Program, Staff Training on Receival methods and acceptance, Cleaning & Sanitation of the receival dock.
  

Our supplier specifications also ask for insect free so maybe this is a ccp ? plus we also audit the suppliers as well.

• For wheat and other grains, your supplier should be providing you with a COA | Certificate of Analysis with every delivery
• How are your suppliers audited?
  

We also fumigate the site on a regular basis to kill off any insects present and also have insect baiting points in place throughout the factory. Im guessing that fumigation is not part of the manufacturing process but should be classed as a pre requisit programme instead, not a CCP?

• A Pest Control Management System should be by default with any company that has wheat and other such grains.
  
• Your Pest Control program should be conducted by professionals, ideally monthly if you are currently having insect issues.
• Your company's general housekeeping should also include a preventative measure for Pest Control
• Pest Control is not a CCP.
  

Hope this helps.

[vinno01]

thats a great reply thanks.

[vinno01]

Ok everyone already talked about how it’s not a CCP so I will talk about the fumigation of your plant are you doing any testing during you are fumigating ,to ensure that you are getting kills throughout your facility? I understand what a pain weevils/insects can be coming from rice. I feel your pain!

[vinno01]

Hi

We purely have baiting points in all packing areas to try to detect background presence. We inspect areas after fumigation for evidence of bodies. fumigation is done every three weeks.

How do you garantee absence of weevil eggs without a CCP before you pack the product.? as in the case of rice.

Vinno

[PaulbSW]

We aspirate the rice but we can’t ever guarantee the absences or the eggs before we pack. But when you say “We inspect areas after fumigation for evidence of bodies.” Are you just look all over to see if you can find dead bugs? I would tell you to look at this website http://www.alteca.com/lsb-products/8/lsb-products. They provide a Fumigation test kit with live bugs. So you can put them in hard to reach areas and see if your fumigation is really effective and give a live/kill count. I really like it and I know my auditor was happy to see that we tested are fumigation against it. hope everyone has given you some good ideas best of luck!