PAC HACCP Project Steering Committee Meeting November 9, 2005

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PAC HACCP ProjectSteering Committee
MeetingNovember 9, 2005
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Official Project Title

• FOOD SAFETY INITIATIVE FOR PACKAGING MATERIALS
  THAT HAVE DIRECT OR INCIDENTIAL CONTACT WITH
  FOODS

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The Food Supply Chain
Consumer
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Packaging Provides The Link
Packages
Farm
Packages
Primary
Packages
Secondary
Packages
Co-mingling
Packages
Cooking
Industrial
Packages
Preparation
Transport Storage
Institutional
Table
Wholesale
Retail
Consumer
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Agenda November 9, 2005
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Please

• Write down your questions
• Participate
• In respect to others at this meeting,
• Turn off or mute your cell phone and pager

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PAC PerspectiveAlan Robinson

• Packaging is a cornerstone of the food industry
• PAC HACCP Project is the result of industry and
  Government working together
• Outstanding contribution by the working committees

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Project History

• Phase 1
• PAC Enabling committee established in 2002 to
  develop an better understanding of the Canadian
  Food Safety Adaptation Program (CFSAP) sponsored
  by Canadian Food Inspection Agency (CFIA)
• Industry meeting held in January 2003 which
  recommended that a project be undertaken to
  enhance the safety aspects of food packaging
  materials
• Phase 2
• CFSAP provided funding for the Phase 1 and 2

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VisionEnabling Committee January 2003
A Canadian food safety program that includes
packaging materials that have been manufactured
to a recognized voluntary standard based on HACCP
principles Industry-wide usage of the standard,
both domestic and imports Recognized Canadian
audit and certification capabilities High
industry / public awareness of the need for a
recognized standard
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Packaging Materials

• Why is HACCP a priority for Canadian package
  converters?
• Food industry focusour customers
• HACCP is the recognized protocol for food safety
• Canada is a huge exporter of foods
• We need to defend out international markets
• Canada is a huge importer of foods
• We need to protect the integrity of food in
  Canada
• We need to ensure a level playing field

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Who are Involved?

• Package suppliers
• converters, importers, brokers
• Raw material suppliers
• Resin, metals, glass, paper, inks, etc.
• Distribution service suppliers
• Transport, warehouses, distribution centers
• Buyers, fillers, users
• They specify the materials

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Expectations

• Canadian industry will use the PAC HACCP Standard
  extensively
• Increased food safety awareness in the packaging
  material converter / supplier community
• Canadian food products will demonstrate superior
  safety characteristics
• Canadian food will continue to be accepted world
  wide
• Food importers will require their suppliers to
  meet the standard

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Phase 2Initial Development

• Started development of the PAC HACCP Voluntary
  Standard in March 2003
• Prerequisites
• Prerequisite Work Book
• Flexible Packaging Standard
• Flexible Packaging Standard Work Book
• 2 Pilot field trials
• Translation into French
• Completed June 2004
• Over 40 companies participated
• Extensive promotional effortsjournal articles,
  website, trade show booth

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Organization 2005-2006
Agriculture and Agri-Food Canada
Packaging Association of Canada
Food Safety HACCP Project
CFSQP
Funding Technical Support
Industry in-kind resources and support
Project Coordinator Packaging Consultant
Food Safety and Food Science Specialists
6 Pilot Field Trials
Paper Working Committee
Steering Communication Committee
Rigid Plastic Working Committee
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CFSQPRandy Bismonte
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Intro to HACCP Dr. Garth Sundeen
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2005-2006 PAC HACCP Project

• Continuing the development of the PAC HACCP
  Voluntary Standard
• Rigid plastics standardinjection and blow
  molding
• Rigid plastics work book
• Translation to French
• 2 pilot field trials for rigid plastics
• Paper Standardcorrugate, boxboard, sheet paper
• Paper work book
• Translation to French
• 3 pilot field trials for paper
• 1 Flexible packaging pilot field trial (will
  make a total of 3 including the previous program)

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2005-2006 Schedule

• Working Committees development March-July 05
• Flexible packaging pilot field trial
  June-December 05
• Translation June-August 05
• Paper and rigid plastic pilot field trials
  September 05-February 06
• Documentation edits March-April 06
• Final report and audits May-Sept 06

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Developing the Standard

• Paul Medeiros
• Guelph Food Technology Centre
• Food Safety Specialists
• HACCP Practitioners

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Development Process

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From the cover of Quality Progress, February
2003, Customer Satisfaction Volume 36, Number 2.
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Development Process
Pre-Req Training
Working Committee Meetings
Complete Revision 2
Working Committee Meetings (2)
Complete Revision 1
Pilot Revision 1
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Development Process
Pre-Req Training
Working Committee Meetings
The Food Connection
Line Clearance and Preparation
Prerequisite Upgrades
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Pilot Preparation Process

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Pilot Preparation Process Scope and Objectives

• Assess draft documents
• Workable, clear, user-friendly, integration, etc
• Identify additional prereq upgrades
• Workable, clear, user-friendly, limitations,
  etc..
• Obtain specific feedback
• Care and maintenance, national/international
  applicability, continuing interest, etc
• Opportunity for plant level HACCP participation

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Pilots and Field Trials

• Scott Wilson Larry Shortt

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Objectives set by standards committees

• Is it workable?
• Is it clear?
• Is it simple?
• Is it user friendly?
• Is it complete?
• Is it effective?
• Is it cost efficient?
• Is it to limited (i.e. did not apply to
  specific converting industry)?
• Does it integrate with other management
  processes?
• Is it well presented and formatted?
• How can it be improved?

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Other comments

• Also, obtain feedback from the pilot facilities
  on the following
• Feedback regarding care and maintenance of the
  standard
• Feedback regarding national and international
  applicability
• Are they still interested in implementing
  HACCP?
• Can it be duplicated at other company
  facilities?
• Do there customers find value in this program?

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What is being reviewed?

• HACCP Toolkit
• Generic Prerequisite Program
• Generic Prerequisite Program Workbook
• Generic HACCP Plan
• Generic HACCP Plan Workbook

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Who are the pilot sites?

• Pilot Sites Paper Standard
• Graphic Packaging
• Jones Packaging (2 plant sites)
• Norampac
• Pilot Sites Rigid and Flexible Plastic
  Standards
• Cousins-Currie
• Plasticap
• Sonoco

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Process

• Guelph Food Technology Centre (GFTC) initial
  contact with plant and project planning
• Conduct initial training sessions
• Participation ranging from 6 to 50 people
• Establish Pilot Site HACCP Team
• Progress meetings facilitated by GFTC Coach
• Review progress
• Provide feedback and guidance to HACCP team
• Conduct Mock Audit
• Submit final reports (End of February 2005)

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Some feedback to date

• Resources required for pilot and timing are a
  challenge
• Overall acceptance of the standard
• Overall understanding of importance of the
  standard
• How standard will be maintained?
• Interest in understanding accreditation or
  certification process

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HACCP - Phase 1

• Food Safety Pre-requisites

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Customer Driven

• HACCP requested for several years
• PAC offered ground level opportunity
• Cross functional Standard development team
• Food Industry
• CFIA
• Packaging Industry
• Folding Paperboard Cartons
• Corrugated
• GFTC

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Management Commitment

• Participation in development
• Pilot implementation (2 plants)
• HACCP Team
• Integrate into GMPs (One system)
• Prepare Gap Analysis to Pre-requisites
• Prepare HACCP budget
• Close the gap
• Implement missing pre-requisites

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Pre-requisites

• Innovative approach
• Rationalize intent of requirements
• Identify the risk
• Eliminate or reduce the risk
• Cost effective
• Meet or exceed intent of the requirements

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Assessment Team

• Conducts Gap Analysis
• Evaluate compliance to intent of Standard
• Prepares HACCP Budget
• Develop integrate HACCP GMPs
• Train Employees

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HACCP- Phase 2

• Conduct Hazard Analysis and identify the Critical
  Control Points

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HACCP - Phase 3

• Monitor program compliance effectiveness
• Apply Continuous Improvement

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ISO 22000-----PAC HACCP interface

• ISO 22000
• Based on Codex Principles
• Lays the groundwork for the prerequisitesdoes
  not offer details or specifics
• Details management roles, internal and external
  communications, resource management, planning,
  infrastructure

• PAC HACCP
• Based on Codex Principles
• Specific to the package conversion processes
• Very detailed and based on FSEP
• Provides shop-floor guidance
• Developed by the packaging community

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Next Steps

• Complete the pilots
• Upgrade the documents
• Continue the communications
• PAC Training workshops

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Continued PAC HACCP Communications

• Communications are key throughout the development
• and after completion
• Website
• Regular PAC communications
• Seminars
• Workshops
• Interviews
• Journal articles

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The Future

• What type of recognition do we need?
• Certification and registration
• Audits and auditors
• Who, how, cost
• Maintaining the Standard
• Who, how, cost
• Promotion and awareness
• Who, how, cost

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2006 and Beyond

• Do we need
• a Standard for metal and glass packaging?
• integration with other food supply chain members?
• a food safety standard for palletsmanufacturing
  and maintenance?
• a food safety standard for packaging machinery?
• a standard for some raw materials?
• a Handbook for HACCP Management?
• A video for awareness and training?

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Responding to Change
Anticipating
Reacting
Crisis
Good

Corporate Stress
COST
Bad
Time
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In ClosingLarry Dworkin

• HACCP is about due diligence
• Are you focused on your final customer?
• Can you defend yourself?
• Do you really have a safe food mindset?

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In Closing

• The future is nowplease get involved--
• PAC can helpjust call us
• Be sure to communicate your HACCP needs with your
  suppliers
• A clear dialogue is needed and formalized
• Remember your customerand your customers
  customer
• Can you afford NOT to participate?
• Reduce your risk.

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Contact Us
Packaging Association of Canada 2255 Sheppard
Avenue East Suite E420 Willowdale, ON M2J
4Y1 Phone [phone] Fax (416)
490-7844 E-Mail info_at_pac.ca Website www.pac.ca
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