Ala. Admin. Code r. 420-3-16-AK
I. THE HACCP SYSTEM INTRODUCTION
7. Establish record-keeping and documentation procedures.
PREREQUISITE PROGRAMS (PPs) - Prior to the implementation of a HACCP Plan, there is a requirement for milk plants, receiving stations, and transfer stations to develop, document and implement written PPs. PPs provide the basic environment and operating conditions that are necessary for the production of safe, wholesome food. Many of the conditions and practices are specified in federal and state regulations and guidelines.
PPs and the HACCP System in total, address public health concerns such as those identified in 21 CFR Part 7, Recalls; Part 110, Good Manufacturing Practices (GMPs); Part 113, Thermally Processed Low-Acid Foods Packaged in Hermetically Sealed Containers; Part 131, Milk and Cream; the Grade “A” PMO; and the current edition of the NACMCF HACCP Principles and Application Guidelines.
SUMMARY - The seven (7) principles of HACCP are also called the HACCP Plan. When combined with the PPs, they constitute a HACCP System. The NCIMS voluntary HACCP Program described in this Appendix includes the HACCP System and other prescribed Grade “A” PMO criteria, such as drug residue testing and trace back; use of milk only from supplies that have been awarded a milk sanitation compliance rating of 90 percent or better or from an acceptable IMS HACCP listed source; and the labeling requirements of Section 4. When properly implemented, the NCIMS voluntary HACCP Program described in this appendix will provide assurance of milk and milk product safety that is equivalent to that provided under the traditional inspection system.
HISTORY OF HACCP - The use of the HACCP System is not new to the dairy industry. HACCP is a logical, simple, effective, but highly structured system of food safety control.
The HACCP System was introduced to the food industry as a spin-off of the space program during the 1960s. The National Aeronautics and Space Administration (NASA) used HACCP to provide assurance of the highest quality available for components of space vehicles. This program to develop assurance of product reliability was carried over into the development of foods for astronauts.
The U.S. Army Natick Laboratories, in conjunction with NASA, began to develop the foods needed for manned space exploration. They contracted with the Pillsbury Company to design and produce the first foods used in space. While Pillsbury struggled with certain problems, such as how to keep food from crumbling in zero gravity, they also undertook the task to come as close as possible to 100 percent assurance that the foods they produced would be free of bacterial or viral pathogens.
Using traditional quality control methods for the food industry was soon proven to be unworkable for the task Pillsbury had undertaken. The degree of safety desired was not provided by the current programs, and the product sampling necessary to provide an adequate degree of safety would have been prohibitive to commercialization of space foods. Pillsbury discarded its standard quality control methods and began an extensive evaluation, in conjunction with NASA and Natick Labs, to evaluate food safety. They soon realized that to be successful they would have to have control over their process, raw materials, environment, and their people. In 1971, they introduced HACCP as a preventive system that enables manufacturers to produce foods with a high degree of assurance that the foods were produced safely.
BACKGROUND - HACCP is a management tool that provides a structured and scientific approach to the control of identified hazards. HACCP is a logical basis for better decision-making with respect to product safety. HACCP has international recognition as an effective means of controlling food safety hazards and is endorsed as such by the joint Food and Agriculture Organization (FAO) of the World Health Organization (WHO) Codex Alimentarius Commission. The U.S. National Advisory Committee on Microbiological Criteria for Foods (NACMCF) has also endorsed it.
The HACCP concept will enable those operating and regulating under a HACCP Plan to move to a preventive approach, whereby potential hazards are identified and controlled in the manufacturing environment, i.e., prevention of product failure. HACCP allows for a preventive, systematic approach to food safety.
VOLUNTARY PARTICIPATION - This Appendix describes a NCIMS voluntary HACCP Program alternative to the traditional inspection system. A milk plant, receiving station, or transfer station may not participate in the NCIMS voluntary HACCP Program unless the Health Officer’s responsible for the oversight of the facility agrees to participate with the milk plant(s), receiving station(s), and transfer station(s) in the NCIMS voluntary HACCP Program. Both parties shall provide written commitment to each other that the necessary resources to support participation in the NCIMS voluntary HACCP Program shall be made available.
Management responsible for both the Health Officer and the milk plant, receiving station, and/or transfer station shall be willing to provide the resources required to develop and implement a successful HACCP System.
HACCP PRINCIPLES - Following are the seven (7) HACCP principles to be included in a HACCP Plan:
II. IMPLEMENTATION OF A HACCP SYSTEM
1. Required PPs - The following required PPs shall have a brief written description or checklist that the PPs can be audited against to ensure compliance. PPs shall include procedures that can be monitored; records that specify what is monitored; and how often it will be monitored.
h. Pest exclusion from the milk plant.
In addition to the required PPs specified above, any other PPs that are being relied upon in the hazard analysis to reduce the likelihood of hazards such that they are not reasonably likely to occur, shall also be monitored, audited, and documented as required PPs.
Each milk plant, receiving station, or transfer station shall have and implement PPs that address conditions and practices before, during, and after processing. The PPs shall address:
3. Required Records - Each milk plant, receiving station, or transfer station shall maintain records that document the monitoring and corrections required by this appendix. These records are subject to the record keeping requirements of this appendix.
HAZARD ANALYSIS - Each milk plant, receiving station, or transfer station shall develop, or have developed for it, a written hazard analysis to determine whether there are milk or milk product hazards that are reasonably likely to occur for each type of milk or milk product processed or handled by the milk plant, receiving station, or transfer station and to identify the control measures that the milk plant, receiving station, or transfer station can apply to control those hazards.
The hazard analysis shall include hazards that can be introduced both within and outside the milk plant, receiving station, or transfer station environment, including hazards that can occur during handling, transportation, processing, and distribution.
A hazard that is reasonably likely to occur is one for which a prudent milk plant, receiving station, or transfer station operator would establish controls because experience, illness data, scientific reports, or other information provide a basis to conclude that there is a reasonable possibility that, in the absence of these controls, the hazard will occur in the particular type of milk or milk product being processed. The hazard analysis shall be developed by an individual(s) trained in accordance with this appendix and shall be subject to the record keeping requirements as described in this appendix.
1. In evaluating what milk or milk product hazards are reasonably likely to occur, at a minimum, consideration should be given to the following:
2. Milk plant, receiving station, or transfer station operators should evaluate product ingredients, processing procedures, packaging, storage, and intended use; facility and equipment function and design; and milk plant sanitation, including employee hygiene, to determine the potential effect of each on the safety of the finished milk or milk product for the intended consumer.
HACCP PLAN
2. Contents of the HACCP Plan - The HACCP Plan shall, at a minimum:
c. List the CCPs for each of the identified hazards, including the appropriate:
3. Sanitation - Sanitation controls may be included in the HACCP Plan. However, to the extent that they are monitored in accordance with the PPs, they need not be included in the HACCP Plan.
CORRECTIVE ACTIONS - Whenever a deviation from a CL occurs, a milk plant, receiving station, or transfer station shall take corrective action by following the procedures set forth in 1 or 2 of this section.
2. When a deviation from a CL occurs, and the milk plant, receiving station, or transfer station does not have a corrective action plan that is appropriate for that deviation, the milk plant, receiving station, or transfer station shall:
3. All corrective actions taken in accordance with this section shall be fully documented in records that are subject to verification.
VERIFICATION AND VALIDATION
1. Every milk plant, receiving station, or transfer station shall verify that the HACCP System is being implemented according to design, except that the milk plant’s APPS or RPPS, respectively, as defined by these rules, shall be managed separately from the NCIMS HACCP System, even if identified as a CCP in the hazard analysis. The milk plant's APPS or RPPS, respectively, shall be inspected by the FDA, or the state regulatory agency when designated by the FDA, in accordance with the applicable requirements of 21 CFR Parts 108, 110, and 113 at a frequency determined by FDA.
a. Verification activities shall include:
(3) A review, including signing and dating by an individual who has been trained in accordance with the training requirements of this appendix, of the records that document.
(iii) The calibrating of any process monitoring instruments used at CCPs and the performance of any periodic end-product or in-process testing that is part of the milk plant, receiving station, or transfer station's verification activities.
The purpose of these reviews shall be, at a minimum, to ensure that the records are complete and that these activities occurred in accordance with the milk plants, receiving stations, or transfer stations written procedures. These reviews shall occur within a reasonable time after the records are made.
2. Validation of the HACCP Plan - Every milk plant, receiving station, or transfer station shall validate that the HACCP Plan is adequate to control hazards that are reasonably likely to occur. This validation shall occur at least once within twelve (12) months after implementation and at least annually thereafter or whenever any changes in the process occur that could affect the hazard analysis or alter the HACCP Plan. Such changes may include changes in the following:
a. Raw materials or source of raw materials; product formulation; processing methods or systems, including computers and their software; packaging; finished product distribution systems; or the intended use or intended consumers of the finished product and consumer complaints.
The validation shall be performed by a qualified individual(s) trained in accordance with the requirements described in this appendix and shall be subject to the record keeping requirements cited below. The HACCP Plan shall be modified immediately whenever a validation reveals that the plan is no longer adequate to fully meet the requirements of this document.
3. Validation of the Hazard Analysis - Whenever a milk plant, receiving station, or transfer station does not have a HACCP Plan, because a hazard analysis has revealed no hazards that are reasonably likely to occur, the milk plant, receiving station or transfer station shall reassess the adequacy of the hazard analysis whenever there are any changes in the process that could reasonably affect whether a hazard exists. Such changes may include changes in the following:
g. Consumer complaints.
A qualified individual(s) trained in accordance with the training requirements of this appendix shall perform the validation.
RECORDS
1. Required Records - It is essential that milk plants, receiving stations, and transfer stations use consistent terminology to identify each piece of equipment, record, document, or other program throughout their written HACCP System. A milk plant, receiving station, or transfer station shall maintain the following records documenting the milk plant, receiving station, or transfer station's HACCP System:
g. Records documenting the ongoing application of the HACCP Plan that include:
2. General Requirements - Records required by this section shall include:
3. Documentation
b. The records in paragraphs 1a-c. of this section shall be signed and dated:
4. Record Retention
PRELIMINARY STEPS - Preliminary steps as listed in the NACMCF document should be followed when producing a HACCP Plan. Complete, up-to-date process flow diagrams are required for all milk and milk products manufactured. Flow diagrams may be combined when processes, products, and hazards are similar.
PREREQUISITE PROGRAM - HACCP is not a stand-alone program, but is part of a larger control system. PPs are the universal procedures used to control the conditions of the milk plant environment that contribute to the overall safety of the milk or milk product. They represent the sum of programs, practices, and procedures that shall be applied to produce and distribute safe milk and milk products in a clean, sanitary environment. They differ from CCPs in that they are basic sanitation programs that reduce the potential occurrence of a milk or milk product safety hazard. Frequently, both HACCP Plan CCPs and PPs control measures are necessary to control a food safety hazard.
HACCP may be implemented only in a facility that is constructed and operated to provide a sanitary environment. Milk plant, receiving station, or transfer station premises, building construction, maintenance, and housekeeping shall be maintained in a manner sufficient to provide such an environment. These factors shall be controlled by effective milk plant, receiving station, or transfer station programs or by PPs, as the milk plant, receiving station, or transfer station chooses.
The exact set of PPs will vary since their application is milk or milk product and process specific. The existence and effectiveness of PPs should be assessed during the design and implementation of each HACCP Plan. PPs should be documented and regularly audited. An audit review consists of verifying that the company has a program implemented that indicates how the company monitors and controls each of the PPs. PPs are established and managed separately from the HACCP Plan.
III. EMPLOYEE EDUCATION AND TRAINING
The success of a HACCP System depends on educating and training management and employees in the importance for their role in producing safe milk and milk products. This should also include information in the control of milk borne hazards related to all stages of dairy production and processing. Specific training activities should include working instructions and procedures that outline the tasks of employees monitoring specific CCPs and PPs.
IV. TRAINING AND STANDARDIZATION
1. Core Curriculum - The Dairy HACCP Core Curriculum consists of:
b. An orientation to the requirements of the NCIMS voluntary HACCP Program.
Basic HACCP training consists of instruction in the application of the NACMCF Principles of HACCP to Food Safety. This training includes practical exercises in conducting a hazard analysis and evaluating potential hazards; in writing a HACCP Plan; and in the validation of the plan. It should be taught by experienced instructors.
The orientation component ideally is coupled with the basic HACCP training but can be taught separately. The content of the orientation will be conducted under the guidance of the NCIMS. It is intended to familiarize industry and regulatory personnel with specific dairy HACCP concerns and the regulatory requirements under the NCIMS voluntary HACCP Program. It is to be taught by instructors experienced in the application of HACCP under the NCIMS voluntary HACCP Program.
The industry individual(s) performing the functions identified in this Appendix requiring training or listed in Part 2 of this section shall have successfully completed appropriate training in the application of HACCP principles to milk and milk product processing at least equivalent to that received under the Dairy HACCP Core Curriculum. Alternatively, job experience may qualify an individual to perform these functions if the experience has provided knowledge at least equivalent to that provided through the standardized curriculum.
2. Industry Personnel - Only industry individuals who have met the requirements of Part 1 of this section shall be responsible for the following functions:
HACCP training for industry and regulatory personnel will be based on the current “Hazard Analysis and Critical Control Point Principles and Application Guidelines” of NACMCF, the current FDA HACCP recommendations, and the regulatory requirements of this appendix and related sections of these rules.
The Health Officer personnel responsible for the evaluation, licensing, and regulatory audits of facilities using the NCIMS voluntary HACCP Program shall have equivalent training to the training required to perform traditional NCIMS functions. They shall also have specialized training in conducting HACCP System audits.
Industry, regulatory, rating, and FDA personnel should be trained together.
HACCP TRAINING
V. HACCP AUDITS AND FOLLOW-UP ACTIONS
1. Pre-Audit Management Interview - Review and discuss the milk plant HACCP System including:
8. Conduct the exit interview.
Note: Examples of Other Applicable NCIMS Requirements:
8. Pasteurization Equipment Design and Installation.
THE HEALTH OFFICER ENFORCEMENT ACTION/FOLLOW-UP
The Health Officer shall:
5. Initiate regulatory enforcement action such as permit suspension, revocation, hearings, court actions, and/or other equivalent measures when the milk plant, receiving station, or transfer station has failed to recognize or correct a deficiency(ies) or nonconformity(ies).
AUDIT TIMEFRAMES
| Audits | Frequency Minimums |
| First Year after Initial Regulatory Audit | Initial audit; next audit in thirty (30) to forty-five (45) days; and four (4) month intervals thereafter, unless the Health Officer determines that a greater frequency is warranted. |
| Subsequent Audits | Every six (6) months unless the Health Officer determines that a greater frequency is warranted*. |
| Compliance Follow-Ups | Compliance follow-ups shall be made as frequently as necessary to assure that problems observed by the Health Officer have been resolved. |
*The Health Officer may elect to extend the minimum audit frequency from four (4) to six (6) months as long as the following conditions exist:
3. No CLEs on the current or prior audit.
Audit Report Form (refer to Appendix M).
REGULATORY AGENCY AUDITS, ENFORCEMENT AUDITS, ACTIONS AND FOLLOW-UP - Audits shall be conducted of the milk plant, receiving station, or transfer station facility, and the NCIMS voluntary HACCP Program to ensure compliance with the HACCP System and other associated NCIMS regulatory requirements.
The audit may be announced at the discretion of the auditor under certain circumstances, i.e., initial audit, follow-up audit, new construction, pasteurizer checks, etc. When unannounced audits are conducted, the audits shall not be completed until appropriate milk plant personnel have had an opportunity to make all pertinent records available for review by the auditor.
AUDITING PROCEDURES
Author: G. M. Gallaspy, Jr.
Statutory Authority: Code of Ala. 1975, §§22-2-2, 22-20-7.
History: Repealed and New Rule: Filed October 18, 2018; effective December 2, 2018.