6 replies to this topic

[maria_esparza-]

Hello everyone! I apologize if this topic is not new, I wasn't able to find anything on the forum. And all in all, I might just be over thinking this process.

 

I am starting out at a very small company, 30 total employees, where they develop new products (flavors) on a monthly basis (that typically only last a month). There are some products that are stable and are made year round. 

 

This company makes ice cream, hard candy, and co-manufactures for both foods as well.

 

I don't know how to approach this task, in getting approvals, specs, and HACCP plans for the company, if it is always changing. I hope I won't have to update the food safety plan on a monthly basis, just to add the new products and possible new ingredients with possible ranging risks.

 

Tracking is also daunting for me. 

 

We are going for our first SQF certification, and I want to be well prepared!

[Tony-C]

Hi Maria,

 

The most relevant SQF requirements are in:

 

Section 2.3.1 Product Formulation and Realization

Clause 2.3.1.3 A food safety plan shall be validated and verified by the site food safety team for each new product and its associated process through conversion to commercial production and distribution or where a change to ingredients, process, or packaging occurs that may impact food safety.

 

Section 2.4.3 Food Safety Plan (Mandatory).

Clause 2.4.3.1 A food safety plan shall be prepared in accordance with the twelve steps identified in the Codex Alimentarius Commission HACCP guidelines. The food safety plan shall be effectively implemented and maintained and shall outline how the site controls and assures food safety of the products or product groups included in the scope of the SQF certification and their associated processes.

 

 

So, answering your question you need a HACCP plan to cover the scope of the products/product groups.

 

Your products ice cream and candy could each be regarded as one product group if they are similar and undergo the same processes. So you may only have two HACCP Plans to maintain.

 

Your HACCP review would then just need to involve looking at any new risks associated with ingredients used for the new flavours. You would need to approve new ingredient and finished product specifications and ensure that they would not be significantly different such that new food safety hazards need to be considered as per 2.3.1 above. For example a significant new risk and the need for a new HACCP plan would be likely if the new ingredient/product would mean introducing a new allergen to the facility.

 

Kind regards,

 

Tony

Edited by Tony-C, Today, 04:22 AM.

[GMO]

Hello Maria!

 

I've always written or supported HACCP plans which were by process not by product.  So if an ingredient changed, the HACCP plan would only change if that changed one of the hazards or processes.

 

In factories like this, I have tended to have a preassessment when a new product was being proposed.  It would include questions along the lines of:

 

Any new ingredients?

Any new suppliers?

Any new allergens?

Is the process changing in any way?

 

Etc.

 

Out of this, we would record that assessment, then decide as a team whether it constituted sufficient change to prompt a HACCP plan review.  We would also then capture upcoming changes on any HACCP meetings (which I have always tended to have minimum quarterly anyway), record upcoming changes and, if that was the case, that the HACCP plan didn't need to change but, for example a new supplier had been approved but no additional risks identified.  Or a supplier audit was required etc.

 

The main thing I always want to see as an auditor (not SQF) is that the risk of change has been considered prior to implementation but that doesn't need to be in a HACCP meeting per se (although I always think it's best practice if it is) but it does need to be recorded how you considered it, who considered it etc.

[kfromNE]

I have an allergen document. Has a list of our products by HACCP plan/Food Safety Plan. Plans are divided by flow/type of item. 

It is the only document I change when we add new items when the process doesn't change. Has our internal code number, the item and allergens. Takes me under 5 minutes to do. 

 

For the ingredients - you will need to do a ingredient hazard analysis. I keep this on a separate document too. I use an excel document and keep it by type of item - how FDA appendix B puts the items together.  

[TimG]

Hi Maria. Off topic but, you have flavors in house that you sell or do you specifically do made to order flavors? Send me a DM..I'm looking for another flavor house for flavored honey projects.

[maria_esparza-]

I truly appreciate everyone's help! These are all great ideas that will definitely help make this smooth and easier. It is just my second week here, so I do look forward to my monthly management meeting where this will be discussed. Since we do monthly new flavors, it will be a great habit to incorporate the HACCP discussion with questions along the lines of GMO's:

 

 

 

"Any new ingredients?

Any new suppliers?

Any new allergens?

Is the process changing in any way?'

 

Thank you!

[maria_esparza-]

Hi Maria. Off topic but, you have flavors in house that you sell or do you specifically do made to order flavors? Send me a DM..I'm looking for another flavor house for flavored honey projects.

 

Hi Tim! I apologize, I do not know how to send a DM through here! Feel free to send me one:)