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ISBN:9780849380280

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简介

Summary: Publisher Summary 1 Clute has been a food management specialist for over 20 years, and he has written this summary of basic quality control program requirements for food science engineers and plant managers who need to address recalls and comply with local, state and federal standards. The author describes safety guidelines for pest control, lot coding, organizational charts, specifications, supplier certification and sanitation and uses the HACCP framework to define current food safety programs. A CD-ROM is included that contains all supporting programs and documentation, including tables, spreadsheets and program outlines. Annotation 漏2009 Book News, Inc., Portland, OR (booknews.com)  

目录

Table Of Contents:
The Author xix
Preface xxi
Chapter 1 Introduction

Top-Down Quality Management 3

The Cost of Quality 5

The Role of Management in Quality Control 6
Chapter 2 Quality: Role and Function 11

The Role of Quality 11

Establishing the Standards or Baseline 11

Measuring Compliance against the Baseline 12

Reporting Noncompliance 13

Sharing the Experience 14

The Quality Control鈥揚roduction Relationship 14

The Secretive and Compartmentalized Relationship 15

The Divisive or Adversarial Relationship 15

The Conciliatory Team-Building Relationship 15

The Quality Control鈥揤endor Relationship 16

The Quality Control鈥揅ustomer Relationship 17

The Quality Control鈥揜egulatory Agency Relationship 18
Chapter 3 Quality Control Systems Development Overview 19

HACCP Manual Cover 23

HACCP Manual Spine Label 24

Quality Control Manual Cover 25

Quality Control Manual Spine Label 26

Pest Control Book 1 Cover 27

Pest Control Book 1 Spine Label 28

Pest Control Book 2 Cover 29

Pest Control Book 2 Spine Label 30

Other Programs Manual Cover 31

Other Programs Manual Spine Label 32

Receiving Manual Cover 33

Receiving Manual Spine Label 34

Shipping Manual Cover 35

Shipping Manual Spine Label 36

Manual Tab Section Labels 37
Chapter 4 Book 1: Hazard Analysis Critical Control Point (HACCP) Program 39

Program Type: Required 39

HACCP Program Planning鈥擳heory 41

HACCP Program Planning鈥擨mplementation 44

Book 1: Section 1 45

HACCP Overview 45

Book 1: Section 2 46

Process Flows 46

Book 1: Section 3 46

Product Description 46

Book 1: Section 4 47

Hazard Analysis 47

Chemical Risk Analysis 48

Example 49

Microbiological Risk Analysis 50

Example 53

Physical Risk Analysis 54

Examples 55

Allergenic Risk Analysis 55

Example 57

Book 1: Section 5 57

Critical Control Point Determination 57

Example 1 60

Example 2 60

Example 3 61

Book 1: Section 5a 61

Control Limit Establishment 61

Corrective Actions 62

Book 1: Section 6 62

HAACP Plan Summary Sheet 62

Example 63

Book 1: Section 7 63

Verification 63

Book 1: Section 8 64

Auditing 64

Book 1: Section 9 65

Training 65

Supplemental Materials 66

General Overview 67

Development and Implementation Team Roster 70

HACCP Team Meeting Attendance 71

Supplier Data Sheet 72

Program Description Worksheet 73

Process Flow Master List 74

Process Flow Template 75

Risk Assessment Worksheet for Chemical Risk Analysis 76

Risk Assessment Worksheet for Microbiological Risk Analysis 77

Risk Assessment Worksheet for Physical Risk Analysis 78

Risk Assessment Worksheet for Allergens Risk Analysis 79

Product/Process Control Point Evaluation Worksheet 80

HACCP Plan Summary Chart 81

HACCP Team Yearly Auditing Meeting Attendance 82

Verification Documentation 83

Examples 84

Supplier Data Sheet 85

HACCP Principle 1 86

Process Flow for Chopped Product A 86

Process Flow for Baked Product A 87

Product Description Worksheet Complete 1 88

Product Description Worksheet Complete 2 89

Chemical Risk Analysis Complete 90

Microbiological Risk Analysis Complete 91

Physical Risk Analysis Complete 92

Allergens Risk Analysis Complete 93

Product/Process Control Point Evaluation Worksheet Complete 1 94

Product/Process Control Point Evaluation Worksheet Complete 2 95

Product/Process Control Point Evaluation Worksheet Complete 3 96

HACCP Plan Summary Chart 97
Chapter 5 Quality Control Program: Overview 99

Theory 99

Application 99

Examples 100

Supplemental Material 101

Quality Control Program: General Overview 102

Quality Monitoring Scheme Examples 107

Quality Monitoring Scheme Examples 108
Chapter 6 Organizational Chart 113

Program Type: Required 113

Theory 113

Application 113

Supplemental Materials 115

Organizational Chart 116
Chapter 7 Good Manufacturing Practices Program 117

Program Type: Required 117

Theory 117

Application 128

GMP Standards 128

Daily Line Check Sheet 131

Supplemental Materials 133

Sanitation Standard 1 134

Sanitation Standard 2 135

Sanitation Standard 3 136

Sanitation Standard 4 137

Sanitation Standard 5 138

Sanitation Standard 6 139

Sanitation Standard 7 140

Sanitation Standard 8 141

Sanitation Standard 9 142

Sanitation Standard 10 143

Sanitation Standard 11 144

Sanitation Standard 12 146

Sanitation Standard 13 147

Sanitation Standard 14 148

Verification Documentation of GMP Standards Training 149

Good Manufacturing Rules 150

Verification Documentation of Employee GMP Annual Review 152

Good Manufacturing Rules: Visitors 153

GMP Audit Procedure/Schedule 155

Good Manufacturing Program 156
Chapter 8 Pest Control Program 157

Program Type: Required 157

Theory 157

Sanitation 158

Mechanical Control 158

Cultural Control 159

Biological Control 159

Chemical Control 159

Application 164

Examples 164

Supplemental Materials 165

Rodent and Pest Control Program 166

Compensation Worksheet 168

Pest Control Contract Example 169

Commercial Applicator License 鈥?Company 171

Certificate of Insurance 172

Label Example 1-3 173

MSDS Example 1-3 177

Plant Diagram Example 184

Rodent/Pest Inspection Form 185

Commercial Applicator License 鈥?Technician 186

Pest Control Service Report Example 187
Chapter 9 Allergen Program 189

Program Type: Required 189

Theory 189

Application 192

Supplemental Materials 194

Risk Analysis Worksheet for Allergen Food Hazards 195

Allergen Information Request Form 196

Allergen Inclusion Chart 198

Daily Plant Sanitation Inspection Form 199

Allergy Testing Form 200

Allergen Testing Program: Initial Training Verification 201

Allergen Testing Program: General Overview 202
Chapter 10 Weight Control Program 205

Program Type: Required 205

Theory 205

Application 206

Examples 207

Supplemental Materials 208

Weight Control Program Overview 209

Weight Control Chart 210

Examples 211

Weight Control Chart Example 212
Chapter 11 Inspection Program 213

Program Type: Required 213

Theory 213

Application 215

Supplemental Materials 217

Inspection Team Roster 218

Monthly Inspection Form 219

Internal Inspection Program: General Overview 220

Daily Plant Sanitation Inspection Form 222
Chapter 12 Sanitation Program 223

Program Type: Required 223

Theory 223

Application 229

Supplemental Materials 231

Master Sanitation Schedule 232

Master Sanitation Schedule: Daily Production 235

Master Sanitation Schedule: Daily Non-Production 236

Master Sanitation Schedule: Weekly Master 237

Master Sanitation Schedule: Monthly Master 238

Master Sanitation Schedule: Yearly, Quarterly, Semi-Yearly 239

Sanitation Procedure Template 240

Sanitation Procedure Training Verification 241

Sanitation Program General Overview 242

Master Sanitation Schedule: Daily Production 243

Master Sanitation Schedule: Daily Non-Production 244

Master Sanitation Schedule: Weekly Master 245

Master Sanitation Schedule: Monthly Master 246
Chapter 13 Metal Detection Program 247

Program Type: Required 247

Theory 247

Placement 247

Size 248

Testing 248

Rejection 249

Application 250

Supplemental Materials 252

Metal Detection Program: General Overview 253

Metal Detector Operation 255

Metal Detection Sheet 257

Foreign Material Investigation Log 258

Metal Detection Training Verification 259
Chapter 14 Regulatory Inspection Program 261

Program Type: Required 261

Theory 261

Application 264

Supplemental Materials 265

Regulatory Inspection Program: General Overview 266
Chapter 15 Lot Coding Program 269

Program Type: Required 269

Theory 269

Application 271

Supplemental Materials 273

Lot Coding Program: General Overview 274

Lot Code Explanation 275
Chapter 16 Customer Complaint Program 277

Program Type: Required 277

Theory 277

Application 280

Supplemental Materials 281

Customer Complaint Form 282

Customer Complaint Flow Diagram 283

Customer Complaint Log 284

Customer Complaint Program: General Overview 285
Chapter 17 Receiving Program 287

Program Type: Required 287

Theory 287

Application 289

Supplemental Materials 290

Receiving Log 291

Receiving Log Directions 292

Verification Documentation: Receiving Ingredient/Packaging Training 294

Receiving Program: General Overview 295
Chapter 18 Shipping Program 297

Program Type: Required 297

Theory 297

Application 298

Supplemental Materials 299

Shipping Container Inspection Log 300

Shipping Log Directions 301

Shipping Program: General Overview 302
Chapter 19 Specification Program 303

Program Type: Optional 303

Theory 303

Raw Material Specifications 303

Processing Specifications 304

Finished Goods Specifications 304

Application 305

Raw Material Specification 305

Finished Goods 305

Supplemental Materials 306

Ingredient Specification 307

Finished Product Specification 309

Certificate of Compliance 310
Chapter 20 Recall Program 313

Program Type: Required 313

Theory 313

Application 317

Supplemental Materials 322

Recall Program Overview 323

Recall Communication 326

Emergency Recall Notification List 327

Raw Material Recall Sheet 328

Finished Product Recall Sheet 329

Effectiveness of Product Recall Sheet 330
Chapter 21 Supplier Certification Program 331

Program Type: Required 331

Theory 331

Application 333

Supplemental Materials 336

Continuing Food Guarantee 337

Request for Evidence of Insurance鈥擵endors 338

Supplier Risk Categorization Sheet 339

Ingredient Supplier and Co-Packer Quality and Safety Survey 340

Ingredient Supplier and Co-Packer Quality and Safety Survey 341

GMP Checklist 342

Food Safety Audit Report 348

Summary of Audit Findings 350

Food Safety/GMP Rating Analysis 351

Food Safety Systems 352

Food Safety and GMP Assessment Rating System 368

Supplier Certification Program: General Overview 369

Supplier Data Sheet 370
Chapter 22 Hold/Defective Material Program 371

Type of Program: Required 371

Theory 371

Application 373

Supplemental Materials 374

Hold Notification 375

Release Notification 376

Destruction Notification 377

Hold Log 378

Release Log 379

Destruction Log 380

Hold/Defective Material Program Cover 381

Hold/Defective Material Program Spine Label 382

Manufacturing Deviation Report 383

Hold/Defective-Material Program: General Overview 384

Hold Tag 386
Chapter 23 Glass, Hard Plastic, and Wood Program 387

Type of Program: Required 387

Theory 387

Application 388

Supplemental Materials 390

Glass/Plastic Inspection Chart 391

Verification Documentation: Glass, Plastic, and Wood Training 392

Glass, Hard Plastic, and Wood Control Program: General Overview 393
Chapter 24 Loose-Material Program 395

Program Type: Required 395

Theory 395

Application 397

Supplemental Materials 398

Color Scheme Chart 399

Loose-Material Control Training Verification 400

Loose-Material Program: General Overview 401
Chapter 25 Microbiology Program 403

Program Type: Optional 403

Theory 403

Application 405

Supplemental Materials 406

Microbiology Program: General Overview 407

Microbiological Testing Log 408
Chapter 26 Security/Biosecurity Program 409

Program Type: Required 409

Theory 409

Management 409

Human Element鈥擲taff 411

Human Element鈥攖he Public 412

Facility 413

Operations 414

Application 414

Supplemental Materials 416

Security Program: General Overview 417

Security/Biosecurity Training Verification 420

Key Check Out Check In Log 421

Visitor Sign In Sheet 422

Visitor Sign In Log Cover 423

Visitor Sign In Log Spine Label 424
Chapter 27 Kosher Program 425

Program Type: Optional 425

Theory 425

Application 426

Supplemental Materials 427

Receiving Kosher List 428
Chapter 28 Organic Program 431

Program Type: Optional 431

Theory 431

Application 434

Supplemental Materials 436

Organic Formulation Submission Form 437
Chapter 29 Environmental Responsibility Program 439

Program Type: Optional 439

Theory 439

Management 439

Hazardous Materials 440

Wastewater 440

Hazardous Waste Handling 440

Air Emissions 440

Waste Management 440

Application 441

Supplemental Materials 442

Environmental Policy 443

Environmental Checklist 444
Chapter 30 Environmental Testing Program 447

Program Type: Optional 447

Theory 447

Application 450

Supplemental Materials 451

Environmental Testing Program: General Overview 452
Chapter 31 Outside Audits 459

Program Type: Optional 459

Theory 459
Chapter 32 Social Responsibility Program 463

Program Type: Optional 463

Theory 463

Application 464

Supplemental Materials 465

Social Responsibility Statement 466
Chapter 33 Continuing Food Guarantee Program 467

Program Type: Required 467

Theory 467

Application 467

Supplemental Materials 469

Continuing Food Guarantee 471

Food and Drug Guarantee 472
Chapter 34 Contract Laboratory Testing Program 473

Program Type: Optional 473

Theory 473

Application 474

Supplemental Materials 475

Chain of Custody 476
Chapter 35 Record Keeping 477

Program Type: Optional 477

Theory 477

Application 477
Chapter 36 Other Forms 479

Program Type: Optional 479

Theory 479

Application 479

Supplemental Materials 480

Confidentiality Agreement 481

Nonconforming Material Report 483

Log of Work-Related Injuries and Illnesses 483

Summary of Work-Related Injuries and Illnesses 485

Injuries and Illnesses Incident Report 486

Credit Application 487

Carrier Seal Policy 489

GMO Inquiry Letter 490

Extended Nutritional Information Inquiry Form 491

Halal Inquiry Letter 492

Affidavit for Ingredients 493

Broker Agreement 494
Index 501

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