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PART 117 – CMP, HARPC AND RBPC
Foodborne Illness in the US
• According to the 2011 CDC report, Estimates of Foodborne Illness in the United States, each year:
– Roughly 1 in 6 Americans (or 48 million people) get sick
– 128,000 are hospitalized
– 3,000 die of foodborne diseases
• Direct effects:
– Economic impact: billions of dollars lost
– FDA is pursuing criminal action in some cases
PART 117 – CMP, HARPC AND RBPC
Recalls by the Numbers, continued
Source: 4th Annual Reportable Foods Registry (2013)
PART 117 – CMP, HARPC AND RBPC
Intent, Scope and Implications of HARPC• From correction to prevention
– Reducing the number of failures
• Back to the basics – 402 (a) (4) from 402 (a) (3)
• Food Safety from “Farm to Fork”– Supply chain applied control
• Global– Food imports
• Responsibility and accountability– Private sector
PART 117 – CMP, HARPC AND RBPC
Are You Ready for the “New” FDA Inspection?• Do you know your rights and obligations?
• Do you have clear written company policies regarding official inspections?
• When will you update the inspection manual?
• Are personnel dedicated to FDA inspections trained?
• Do you have other knowledgeable personnel?
PART 117 – CMP, HARPC AND RBPC
5 Key Elements of FSMA
FSMA
Prevention
Inspection and
Compliance
ResponseImports
Enhanced Relationships
PART 117 – CMP, HARPC AND RBPC
How Good are Your Records?
• What are your record preparation and keeping practices?
• Do your records reflect the real conditions under which the product was manufactured?
• Are they audit proof?
PART 117 – CMP, HARPC AND RBPC
Automatic Access to Records
• What “automatic access” means:
– Records in plain sight
• Including those kept electronically
– Records of interstate/international commerce
• Shipping and receiving
• Traceability
PART 117 – CMP, HARPC AND RBPC
Situational Access to Records
• What “situational access” means:
– Under FSMA, the FDA can now access any of a facility’s records related to the manufacturing of a product, and copy them when it has “reason to believe” an article of food:
• Is/could be adulterated
• Is/could misbranded
• Suspected of being able to cause SAHCODHA
– Records must be made available within 24 hours
PART 117 – CMP, HARPC AND RBPC
Inspections, continued
• Enforcement oriented
– More minor findings being listed on Form 483
– Increased use of warning letters
– Actions for injunction
– Park Doctrine and criminal liability
PART 117 – CMP, HARPC AND RBPC
Inspection Results
• Inspection results between 10/1/12 – 9/30/13
– Number of food F483s issued = 2386 (47%)
• Top six issues (56% of the 2386 issued)
1. Lack of effective pest exclusion
2. Sanitation monitoring
• Failure to maintain hand washing, hand sanitizing, and toilet facilities
• Failure to protect food, food packaging material, and food contact surfaces from adulteration
PART 117 – CMP, HARPC AND RBPC
RFR, continued
• The RFR:
– Requires a responsible party to file a report through the RFR electronic portal when there is a reasonable probability that the use of, or exposure to, an article of food will cause serious adverse health consequences or death to humans or animals (SAHCODHA)
PART 117 – CMP, HARPC AND RBPC
Educate, Educate, Educate
• What is your time table for continuous education of all personnel on FSMA?
– The basics
– What’s new under FSMA
• Qualified Individuals
– The expectations
PART 117 – CMP, HARPC AND RBPC
Emphasis for Revision
• Records Maintenance and Access
–Records required to be maintained and available for inspection
• Employee training records
• Allergen control plans
• Environmental pathogen control plans
• Sanitation procedures
PART 117 – CMP, HARPC AND RBPC
Emphasis for Revision
• Written Sanitation Procedures
–Develop written procedures for all food contact equipment and surfaces
• Define scope
• Objective
• Management responsibility
• Monitoring
• Corrective action and record keeping
PART 117 – CMP, HARPC AND RBPC
FDA Regulation
• Part 110.40, Equipment and Utensils
– Equipment - Clean Design
– Installed for Cleanability
– Installed to Prevent Contamination
–Closed Systems Maintained
– Freezer and Cooler Thermometers
–Production Instrumentation Accurate
–Compressed Gas / Air Filtered
PART 117 – CMP, HARPC AND RBPC
Preventive Controls Qualified Individual
• FDA-recognized training
– FSPCA (Food Safety Preventive Controls Alliance)
– Train lead instructor(s) to subsequently train employees
– Or otherwise qualified (training/experience)
Annex A, Page 8
PART 117 – CMP, HARPC AND RBPC
Preventive Controls Qualified Individual
To do or oversee:– Preparation of a Food Safety Plan– Validation of Preventive Controls– Review of records for implementation and
effectiveness of – Preventive Controls– Appropriateness of corrective actions– Reanalysis of Food Safety Plan– FDA will assess qualified individuals (real plant
conditions vs. records)– What will you present to the FDA?
PART 117 – CMP, HARPC AND RBPC
Your Food Safety Plan
Must include:
– Hazard analysis methodology & results
– Identification of preventive controls
– Supply chain program as required
– Recall plan
– Monitoring, corrective action, and verification procedures
– Validation
Annex A, page 30
PART 117 – CMP, HARPC AND RBPC
Your Food Safety Plan
• “Written” means
– Food Safety Plan
– Procedures & records
• Must be prepared or overseen by one or more Preventive Controls Qualified Individuals (PCQI)
• The owner, operator, or agent in charge of the facility must sign and date the food safety plan:
– Upon initial completion and
– Upon any modification
Annex A, page 30 & 54
PART 117 – CMP, HARPC AND RBPC
HARPC Development Requirements• Must be written regardless of outcome
• Must be based on experience, illness data (recalls), scientific papers, including guidance documents and other information
• Must include raw materials/ingredients, process and environment
• Must consider specific factors cited in the rule
• Must identify “known or foreseeable hazards”
– Includes B, C, P, radiological and EMA
• Must complete a risk analysis to identify who will control the hazard and the appropriate control
PART 117 – CMP, HARPC AND RBPC
The 12 Categories of Hazards Under HARPC
What are they?
1. Biological 7. Drug Residues
2. Chemical 8. Decomposition
3. Physical 9. Parasites
4. Radiological 10. Allergens (Human Food only)
5. Natural Toxins 11. Unapproved Additives
6. Pesticides 12. Intentional
Answer
PART 117 – CMP, HARPC AND RBPC
The 12 Categories of Hazards Under HARPC
BiologicalParasites
ChemicalNatural Toxins PesticidesDrug Residue AllergensDecomposition Unapproved Additives
Physical
Hazards not covered under HACCP
• Radiological• Intentional: EMA
PART 117 – CMP, HARPC AND RBPC
Risk-Based Preventive Controls
Potential PCs:Prerequisite Programs
• Sanitation
• Personnel practices
• Chemical control
• Allergen control
• Maintenance
• Water quality
• Environmental monitoring
• Supplier control
• Other
Process Steps:
• Cooking
• Cooling
• Strainers/Sifting
• Metal detection
• Bottle Washing
• Ozone or UV treatment
• Optical scanner
• Irradiation
• Sanitizing
• Other
Specific operational and non-operational activities:
• Temperature
• Change over cleaning
• Calibration
• Rework
• Hand washing
• Rinse water pH
• Pre-op/operational inspection
• Other
PART 117 – CMP, HARPC AND RBPC
Environmental Risk Assessment
The hazard evaluation must include an assessment
– of environmental pathogens whenever a ready-to-eat (RTE) food is exposed to the environment prior to packaging and the packaged food does not receive a pathogen reduction treatment.
– or otherwise includes a control measure (such as a formulation lethal to the pathogen) that would significantly minimize the pathogen.
Annex A, Page 4
PART 117 – CMP, HARPC AND RBPC
PC Management Components
Monitoring Procedures
– To ensure Preventive Controls are consistently performed
• What is being controlled
• How is this being done
• When or the frequency of checking
• Who will be responsible for this activity
PART 117 – CMP, HARPC AND RBPC
PC Management Components
Corrective action procedures must describe the steps to be taken to insure that:
• The PC violation is identified, recorded and corrected
• Reduce the likelihood that the problem will recur
• All affected food is evaluated for safety and
• Affected food is prevented from entering commerce if you cannot ensure that the food is not adulterated or misbranded (labeling)
PART 117 – CMP, HARPC AND RBPC
Managing Preventive Controls
. . .allow flexibility for the application of management elements for preventive controls so that such controls are managed with a level of rigor commensurate to the nature of the risk and the type of control employed..
“Levels of oversight should align with the risk and type of Preventive Control”
PART 117 – CMP, HARPC AND RBPC
Role Environmental Monitoring
• Verifies PCs are preventing unsanitary condition(s)
– Roof leaks, standing water, condensate, pathogen harborage in building structure (floors, walls) or equipment, utensils & equipment (contact & noncontact), cleaning not effective, unsanitary plant conditions, etc.
• Done “as appropriate” for RTE foods
• The goal is to know where problems are and correct them = find root causes and eliminate them
PART 117 – CMP, HARPC AND RBPC
Role of Product Testing
• “Product” means ingredients, in-process and finished product
• Seen as a verification activity
– Verifies consistency and effectiveness of preventive control(s)
– Applicable to Ready to Eat (RTE) products
• Done “as appropriate” for type of food
– Kill step, allergen cleaning, cross contact, supplier verification, etc.
• Requires procedures, corrective actions and recordkeeping if used
PART 117 – CMP, HARPC AND RBPC
Go Back to the Basics
• Assess facility and assure that the following are in place applied consistently, part of the culture:
– Sanitation
– Allergen control and
– GMP compliance
• Assess effectiveness of “corrective action”
– Assure root cause elimination and not just treating the symptoms
• Get a “fresh” outside look at your facility
PART 117 – CMP, HARPC AND RBPC
Assess Your FSMA Readiness
• Do you have the key elements in place, and how robust are they?
• Preventive controls
– Process PCs
– Sanitation PCs
– Allergen PCs
– Supply chain control
– Others as defined by the Hazard Analysis (glass jars, etc.)
PART 117 – CMP, HARPC AND RBPC
Integrating HARPC and HACCP
HARPC
– Similar concepts to HACCP!
– Somewhat different from HACCP!
– Include in HACCP, subset or separate?
– What to do?
PART 117 – CMP, HARPC AND RBPC
HARPC = or ≠ HACCP?HACCP HARPC Solutions
International Codex 21 CFR Part 117
HACCP Team and Coordinator
Preventive Control QualifiedIndividual(s)
Flow diagram required and verified on the floor
Not required
Product description, intended use, and technical parameters
Product and technical parameters
3 hazards, B, C, and P 12 hazards + intentional + EMA
Hazard Analysis by team
Hazard Analysis by PCQI with FDA Guidance
PART 117 – CMP, HARPC AND RBPC
HARPC = or ≠ HACCP?HACCP HARPC Solutions
Identifies CriticalControl Points (CCPs)
Identifies Risk-Based Preventive Controls (PCs)
Requires critical limits for CCPs
Requires parameters for RBPCs, as appropriate
CCPs must bevalidated
Validation of RBPCs, as appropriate
Requires verification / validation
As appropriate, verification / validation
CCP corrective action: reprocess, animal food or destroy
RBPC corrective actionallows for product evaluation
PART 117 – CMP, HARPC AND RBPC
HARPC = or ≠ HACCP?HACCP HARPC Solutions
Specificdocumented monitoring and corrective action
Documented monitoring with flexibility
Reassess whenchanges occur and yearly validation
Reassess when changes occur and every three years
Does not require check on supplier regulatory compliance
If supplier controls used, must include verification activities, including regulatorycompliance history
Finished product testing not required for validated kill steps
As appropriate,product testing e.g. (RTE)
PART 117 – CMP, HARPC AND RBPC
Your Options
• FDA does not require a HACCP Program
– Except seafood, juice
• It is an OPTION to eliminate your HACCP Program, however:
• Reasons to retain a HACCP Program:
– Recognized/required by domestic and foreign customers
– AIB requirement
– GFSI requirement (BRC, SQF, IFS, FSSC 22000)
– Retain emphasis on food safety culture
What’s Next?
Until November 2016 to come into compliance.Set up a transition team
Obtain, study and understand the final rule.Obtain, study and apply applicable guidance
documents.Undertake the hazard evaluation.
Who will control the hazards needing a PCWhat will be the PCs
Develop the written Food Safety Plan.Integrate HACCP and HARPC? – options.
Make sure you engender Qualified Individuals.