HACCP/BRCGS and Hygiene Quality Awareness training

2019 version 2
In compliance with BRC S&D issue 3 and BRC A&B issue 2
 HACCP/BRCGS
and Hygiene
Quality Awareness training 2019
In compliance with BRC S&D issue 3 and BRC A&B issue 2

Duration: 45 min

Mobile phones on silent please

Source: N&S Quality -Zaltbommel

 Agenda

• What is HACCP/BRCGS?
• Why carry out HACCP/BRCGS training?
• Hazards
• Measures for control
• Certifications
• Instructions for drivers
 Why HACCP/BRCGS & Hygiene course

• Promote Hygiene Awareness

• Prevent contamination caused by:
– Lack of knowledge
– Lack of care and attention
– Lack of hygiene
– Failure to maintain correct temperature
• Ensure safe delivery of product to the
customer in good quality
• Ensure competency of staff
 Certification Standards
Recognised by Global Food Safety Initiative

• HACCP Hazard Analysis Critical Control Points

• BRCGS British Retail Consortium Global Standard

– BRC Storage & Distribution Standard applies to the Temperature Controlled Activity in Europoort, where we operate
our own Reefer trailers.
– BRC Agents & Brokers Standard applies to the services supplied by the Control Tower in Amsterdam and the Dover
office, which utilises third party sub-contract hauliers who use their own equipment.
• IFS International Food Standard
• FSSC 22000 Food Safety System Certification 22000, based on ISO
 What is HACCP/BRCGS ?

• Origin
• Mapping product and process
• Identify hazards to public health and set
standards
• Risk-analysis
• Control method indication
• Protection procedures
• Documentation
 Background and Scope

• British Retail Consortium Global • To demonstrate to our customers that

Standards (BRCGS) specify that P&O Ferrymasters transport their
businesses must have a full products in a safe and secure way, we
understanding of the products handled hold two BRCGS certifications; BRC
Storage and Distribution and BRC
and transported and have systems in Agents and Brokers for the
place to control hazards significant to transportation of ambient, chilled and
the safety and quality of the products. frozen packed food products.
 Certification - requirements

• Manufacturers, food companies and suppliers must have a valid food safety system,
such as HACCP / BRCGS certification.
• All companies involved in the supply chain must comply to this standard.
• BRC S&D and A&B Gradation AA, A, B, C, D in line with BRC food certification
• Possibility to participate in unannounced audits. This is also in line with the BRC Food
certification. When participating a “+” is added to the grade. (for example, AA+)
 Certification - Audits

• Document Control
• Initial visits
• Follow up visits
• Possibility of un-expected visit by ‘BRC auditor’

Results of external audit?

All audits must have a positive result!
Certificate
 Internal audits

• Checking application of food safety controls and compliance with company policies
and procedures (to be found on the intranet).
• Be honest and learn from the shortcomings
• Preparation for certification
• Create and increase ownership and engagement
• Internal audit to cover, product security / food defence and product fraud mitigation
plans.
Risk Assessments
 Hazards

• Not following company and client procedures

• Improper Haulier approval and subcontractor management
– using hauliers other than those approved for Foodstuffs by POFM
• Not receiving or giving the correct instructions
• Lack of engagement from management and employees
• Equipment does not comply to required standards
• Failure to set / monitor temperature in Reefer trailers and complete / control Driver Reports.
• Failure to log incidents, investigate and implement corrective actions to prevent re-occurance
• Lack of employee awareness and knowledge
 Control measures

• Identification of CCP’s
• Control processes and procedures
• Management of Suppliers
• Cleaning programs
• Equipment Maintenance and Calibration
• Temperature controls and checks
• Supply of controlled, calibrated temperature probes to drivers of POFM reefer trailers.
• Deviation and incident management
• Pest Control and Waste management (more specified in S&D V3 standard)
• Hygiene rules for drivers
 CCP’s in Transport

• Critical control points (as applicable);

• Temperature control (calibrated measuring equipment)
• Hygiene
• Prevention of contamination (illegal immigrants)
• Use of authorized Hauliers with trained drivers
• Product damage during transit (load securing)
• These points must be checked and documented!
• Any deviations must be reported immediately to your manager
Food Safety Hazards
 Why practice good hygiene (1)

• Approx. 2 mil. People become ill each year

by contaminated food
(Bron Nationaalkompas, based on Netherlands, population of circa 16
mil)

• 80 deaths each year by contaminated food

(Bron Nationaalkompas, based on Netherlands, population of circa 16
mil)
 Why practice good hygiene (2)

• €220 mil. Financial damage

• Recalled products
• Quality reduction
• Damage to company reputation
• Claims
• Fines / Official warnings Nederlandse Voedsel en Waren Autoriteit (NVWA)
– It is not allowed to do transports for clients in the food industry without HACCP/BRC Quality Systems!!
• Requirement of clients
 HACCP / BRCGS

• The substances or objects that may

cause harm to your health which are
undesirable we call contaminants.

• There are several types of contaminants

such as :
• Physical
• Chemical
• Microbiologica
 Physical Contaminants

• Remnants from previous products

• powders, dusts, sand, wood
• Nails and Screws
• Glass
• Cigarrete butts
• Fragments from tools
• Other physical items
 Chemical Contaminants

• Residues:
• Cleaning products
• Lubricating oils
• Coolants
• Plant protection products
• Fertilizers

• Chemical contamination is often not noticed by

the consumer: it may be substances without
odour, colour or taste in small quantities and can
seriously damage health
 Microbiological Hazards

• (1 gram = 100,000 billion pieces)

• Fungi
• Yeasts
• Bacteria

Micro-organisms may be desirable and

undesirable in food products
 What are micro-organisms?

Salmonella Staphylococci E. coli

 Growth of bacteria

Time Amount
•1 hr 8
•2 hr 64
•3 hr 512
•4 hr 4.096
•5 hr 32.768
•6 hr 262.144
•7 hr 2.097.152
•8 hr 16.777.216
•9 hr 134.217.278
•10 hr 1.073.741.824
Registered cases of Food Poisoning by Bacteria
 Allergens

• An allergen is a component of a natural, or artificial substance which may cause

allergic reactions. Symptoms may include a runny nose, watery eyes, itching or
tightness. Allergic reactions are often related to conditions such as eczema (skin
reactions) and asthma (respiratory reactions).

• The number of substances that can act as an allergen is virtually unlimited.

 Food Defence and Fraud, theft, or substitution

The following factors can increase the risk of fraud or theft of food products:-
•National or European shortage of product supply = higher value of product
•Desirability of products
•Economic conditions = higher unemployment, low wages
•Changes in taxation = increases taxes on specific products
•Security breach by illegal immigrants during transit = contamination of product
Traceability, Recalls and Incidents
 Incidents (Negative Publicity)

• Sweet manufacturer Mars carried out a major recall in 55 countries when pieces of
plastic were found in a Mars bar in Germany. Accordingly products from brands Mars,
Snickers, Milky Way, Mini Celebrations and Mini Mix were recalled from the shops.
• 4 million bars in the Netherlands and 10 million in Germany. It is the first time Mars
carried out a recall from their factory in the Netherlands. It works closely with the NVWA
and retailers to recall the bars in this batch, from the supply chain, as quickly and
completely as possible. Thereafter, the chocolate was destroyed.
• Lactalis factory in Craon, due to salmonella bacteria in baby food three dozen infants in
France have been confirmed sick and a number of children in Spain and Greece may be
sick from contaminated Lactalis products.
 Offerman (Listeria Incident) - Jumbo
Update December 2019

• Bacteria was already discovered in 2017 but below tolerance

• Caused by machines not cleaned properly
• October 2019 incidents were escalated following 3 fatalities 1 miscarriage and 20
people got serious ill
• Huge recall; 400 different meat products, total weight 300.000kg
• Factory was immediatly closed beginning of October 2019
• 100 employees in fear of losing their job
Traceability & recall
 Traceability & recall

• Everything must be traceable (including raw materials and primary packaging)

• Full traceability should be completed within 4 hours
• The recall procedure should focus on communication with customers (communication
plan)
• Identification: everything must be encoded
• Decide on recalling and report to authorities and certification bodies (NVWA and DNV)
• Register what is done with return product
• The suppliers shall have an effective traceability system. If a supplier has been approved
based on a questionnaire, a legally enforceable contract shall be in place. Verification of
the supplier’s traceability system shall be carried out at the time of the initial approval and
then at least every 3 years.
 Complaints and Incidents

• In emergency situations immediately notify

POFM, who will inform the client
• What are the complaints?
• Register complaints in the incident tab (fr8
orders)
• Detect deviations and report to your manager
• Investigate and close out incidents and
complaints in fr8orders
• Make sure you learn from mistakes
Food Safety Controls
 Management of Suppliers – BRC

Charter Haulier Asset haulier

13. Carrier Questionnaire Carriage of 7. Haulier Questionnaire
foodstuffs Haulier Name

Haulier Code
Carrier Questionnaire for the
Carriage of Foodstuffs and Food grade packaging Products under BRC

All trailers
Evidence
Question Yes / No Evidence Required attached Comments
(Yes / No)
Please provide BRC S&D certification or
Copy of Certificate
equivalent HACCP certification
Please confirm you have a Service / Copy of Service
Maintenance programme for trucks & Report for
trailers. nominated Truck
Please confirm you have a Defect Evidence of defect
Reporting procedure being recorded
Please confirm you have a Defect Evidence of defect
Rectification process being repaired
Please confirm you have Pre-start checks Evidence of pre-
for Drivers start check
Please confirm Trailers are sealed or
N/A
padlocked
Details of tracking
Please confirm you have a Track and Trace
system. Sign up for
system for Trucks and / or Trailers
GateHouse
Please confirm you comply with the
Document
Instructions to Subcontractors - section 12.
Attached. Please
Transport of Packaged Food related
sign to confirm
Products and Food Grade Packaging.
Name

Position

Date

Approval procedures can be found on the

Refrigerated Trailers (Frozen / chilled movements)
Evidence
Question Yes / No Evidence Required attached Comments
(Yes / No)
Please confirm you provide Food Safety
Example of
and Hygiene awareness instructions to
instructions given
drivers.
Please confirm you provide instructions in Example of

intranet: > Logistics Service Providers

emergency incidents. instructions given
Please confirm you have instructions to
follow in the event that the load is to be
Example of
returned to the customer, or alternative
instructions given
location, due to a problem effecting the
quality of the product
Sample of a
temperature read
Data logging of temperature during journey
out for a selected

Foodstuff
vehicle
Temperature logging equipment calibrated
N/A
annually
Example of
Instruction in cleanliness of PPE.
instructions given
Instruction in visibility of jewellery,
Example of
glass/hard plastics and use of snap off
instructions given
blade knives.
Instruction in the use of reefer trailers, the
Example of
trailer cleaning programme and where to

Audits, training, probes

instructions given
clean.
Name

Position

Date

P&O Ferrymasters may audit carriers to confirm that the above requirements are met. Version 6.0 January 2019
 Cleaning Programs

• Schedule: daily, weekly, monthly or yearly

• What to clean
• Which products to use
• Who does the cleaning
• How often
• Record and document the check!
• Cleaning station questionnaire returns to
confirm station complies with Food Safety
standard
 Hygiene regulations (1)

• Clean Clothing
• No Smoking, eating, chewing and
drinking during loading and unloading
• Do not wear jewellery
• Wash hands frequently
  (After breaks and after toilet visits)
• Clean equipment
• Open wounds must be covered with
plaster
 Hygiene regulations (2)

• Report incidents of contamination to management: pests, glass and hard plastic

• Inform management in case of infectious diseases (such as Diarrhoea) and skin
complaints
• Comply with site rules. This may include wearing protective coats, gloves and hair
nets in the production areas
• Avoid coughing on uncovered foods
• Avoiding touching the products
 Precautions

• In places where hand hygiene is crucial,

the following precautions are necessary:
• Keep finger nails short and clean
• No gel or plastic nails
• Remove all nail polish in advance
• Do not wear hand or wrist jewellery,
watches etc.
• Remember to also thoroughly wash the
wrists and forearms
 Handwashing Guidance

• Wet your hands

• Take a dose of soap in the palm
• Rub the palms well for at least 30 seconds each
• Turn right thumb movement on the left palm.
• Left palm over back of right hand.
• Turn fingers on the palm of the other hand.
• Palms crossed, fingers spread.
• Dry hands
 Certain areas need special attention when washing hands

Often forgotten

Is frequently forgotten

Normally well cleaned

Back of hand Palm

 Equipment requirements for All trailers

• Check trailer is clean (swept inside)

• Check there is no residual smell from previous product
• Check trailer condition:
- trailer floor for loose nails and defects
- curtains and roof for holes and tears (check it is watertight)
• Check TIR cord is present (where applicable)
 Operational Instructions for All trailers

• After loading, seal trailer with TIR Cord, or lock trailer with padlock
• Record seal number on CMR in presence of loading team
• On route to port or rail terminal:-
– Complete checks in line with UK Border Force Checklist
– Plan to avoid overnight rest and stops within 150km of Ports.
• Refer to Illegal Immigrant instructions:
• http://www.poferrymasters.com/customers-and-partners/partner-information/instructio
ns-for-subcontractors
 Equipment requirements for Reefer Trailers

• Trailers must comply with legal standards, maintenance, cleaning, FRC checks (for
reefer trailers)
• Calibrated temperature monitoring and recording equipment
• No fragile glass (example light in reefer trailers)
• No wood (except pallets)
 Maintenance/Calibration for Reefer Trailers

• Calibration of measuring equipment (e.g. temperature probes)

• When servicing equipment use only "suitable for food’’ oils / lubricants
• External technicians must comply with hygiene rules
• Be aware of loose equipment
 Specific instructions for Reefer Trailers

• The following two slides are an extract from our Haulier Handbook and Instructions
to Subcontractors.
• The operation of Reefer Trailers is a specialised activity
• The consequences of incidents can be dangerous to health and are costly.
• Reefer trailers are far more expensive than euroliner trailers and specific knowledge
is required.
Haulier Handbook
Haulier Handbook
Haulier Handbook
Instructions to Subcontractors
Instructions to Subcontractors
 The basics (POFM Reefer Trailers)

• Instructions in the Haulier Handbook states that temperature checks during transport
are very important. However, this only has value when it is accurately documented on
the Drivers Report; an example of a Driver Report is included in this training

• For cleaning trailers the same applies; F.e. contamination from a previous load, for
example, is a great danger
 Food defence

• There must be a food defence analysis and vulnerability assessment

• Included in our procedures (to be found on the intranet)

 Fraud, theft, or substitution

• Included in Risk Assessment

• Consignor confirms quantity, product on CMR paperwork given to driver and driver
cross references with instructions provided by P&O Ferrymasters. Trailers sealed
after loading, until delivery.
When unable to check at collection please
remark cmr “unable to check at loading”
 Quality checks / incidents

Points of attention for drivers at collection and delivery;

• Check trailer is clean and free from odour condensation and document this
• Temperature of product and temperature settings
• Quality of Product (decay, contamination, pests)
• Personal and site hygiene rules
• Report incidents immediately

• If driver is not allowed to be present at loading or unloading?

Write comment on CMR and pass to the planning!
 Driver manual for cooling units (POFM Reefers)

• The next slide will give brief instruction on the Schmitz cooling units fitted to POFM
reefer trailers.

• Make sure there is sufficient diesel in the trailer tank!

• Any doubts about the functioning of the
cooler contact the operations
immediately

• When an error code appears on the

display seek guidance Do not try to
solve this by yourself!
 Thanks for your attention

Questions