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HACCP Case Studies

Dry Food Products Manufacturer

The requirement – ISO 9001:2008 and ISO 22000:2005 implementation. Our client required implementation of the above standards but required confirmation their systems and procedures were correct first.

The solution - Using our expert knowledge and experience of food manufacturing businesses, their existing systems and procedures were assessed and improved as necessary this removed unnecessary documentation and streamlined existing processes, thus ensuring all processes were safe, hygienic and efficient, whilst maintaining a profitable business. Their HACCP and pre-requisite programme were refined and tested (validated and verified) in accordance with the requirements of the ISO 22000.

All staff were trained in CIEH accredited food hygiene for manufacturers, and key staff were trained to Level 4 in HACCP for manufacturing principles and internal auditing skills specifically tailored for food businesses.

Using our retained service provision, the client, has quadrupled their turnover and have secured contracts which they would not have received without their certifications in ISO 9001 and ISO 22000.  They maintain their ongoing commitment to those systems through regular internal audits, undertaken by HACCP UK and we are also members of their food safety team providing the benefit of our expert input into their monthly food safety team meetings.

Large Government Facilities Group

The requirement – We were asked to be involved in these audits for their continuing ISO 9001:2008 certification due to our expertise in auditing food businesses, as this department has the school meals provision responsibility for school meals provision across the county.

The solution - All aspects of the service were considered from their management objectives, the resource management to achieve those objectives, and their progress towards achieving those objectives, through to 'on the job' aspects involving audits of several school sites to ensure that the systems were being maintained at all levels. This could not have been achieved in this environment without expert food hygiene knowledge.

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Event Catering Operation

The requirement – The client provide expert catering services to large events and functions.  They required an independent assessment of their existing HACCP system and procedures in order to satisfy customers, whilst they continued to expand into new markets affiliating with larger event and function venues.

The solution - HACCP UK audited their existing systems, procedures and production kitchens and supplied a report with tangible solutions which they then implemented. Jush Events have since secured some of their desired contracts as a result of using HACCP UK’s expertise.

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Manufacturer of High Risk Dairy Products

The requirement – Our client produces high risk dairy products for international distribution.  They required their existing HACCP system to be verified for accuracy.

The solution - HACCP UK verified their HACCP by benchmarking against their processes.  We also updated and reproduced their HACCP in a standardised format.  This made their food safety management system more user friendly for staff and management and also easier to audit.

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Contract Catering for the Leisure Sector

Providing catering services for Theatre and Event Venues, this large catering company required a compliance audit in order to maintain their supplier status. HACCP UK provided this service and their supplier status was maintained.

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Innovative and Novel Foods Developer

Carry out research into food manufacturing operations and also product development.   Under the wing of The University of Nottingham, it was important to them to implement an accredited ISO 9001 with a food safety management system bias.  HACCP UK provided an initial benchmarking audit and will carry out a further audit later this year to ensure that their certification will be awarded.

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International Audit Registrars

We provide auditing services for UKAS accredited registrars, consisting of UKAS compliant audits of food centric businesses both in the UK and internationally. We also provide ‘peer review’ audit services for other auditors across the world who have executed Food Safety Management Systems Audits ISO22000, which obviously incorporates these company's HACCP plans. 

We were also asked to sit on their Governing Board, a steering group which directly influences the future direction of their business internationally.  This group meets four times a year and we bring expert Food Hygiene and Food Business knowledge to these pivotal meetings.

In addition, we provide training as part of food consultancy in HACCP principles and internal auditor training.

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Ice Cream Manufacturer

An ice cream producer required a review of their existing systems, procedures and HACCP in order to attract a new customer base. Located on a working farm, it was therefore essential to ensure that safe and hygienic processes were in place, and effective segregation of the two were being properly managed. HACCP UK audited their production operations and existing management systems, including their existing control procedures to produce an effective HACCP and pre-requisites programme which was accurate to their day-to-day activity and satisfied the requirements of their expanding customer base.

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Fish Mongers and Fish Product Manufacturer

Scope: to ensure that the retail shop were operating safely and to set up the operation of the fish products manufacturing in readiness for Approval and an EC number to be allocated. The manufacturing facility began with plans being drawn up which HACCP UK advised on structure and layout of the facility. Once the facility had been created, then the HACCP plans and underpinning PRP’s were written, along with day to day monitoring documentation. In addition, we attended providing expert advice when the Local Enforcement Authority visited in readiness for the Product’s Approval Visit, whereby the EC number is issued.

HACCP UK’s expertise enabled the new manufacturing facility to be operational within a short space of time and able to produce products for sale in the group’s retail outlets. Plus it placed them in a position where they were ready to apply for Product’s Approval and gain their EC number when they were ready to do so.

This client has now been so successful that they are doubling the size of their manufacturing facility and we are continuing to work with them to ensure that this will be up and running within the shortest time possible.

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Fish Restaurant in Mayfair

Scope: To create an entire documented food safety management system for all aspects of the operation within a restricted timeframe and to gain a 5 star rating upon first enforcement inspection.

We created the entire documented food safety management system for this large, top class restaurant, which is regularly patronised by celebrities, therefore the quality and safety of their food had to be second to none. Thus they engaged HACCP UK as their preferred specialist food safety management consultants to ensure their food safety management was exemplary. We also advised on kitchen structure, layout and raw and ready to eat zoned areas, and also the satellite plating up areas, together with the ‘live’ tank, raw fish display area and sushi preparation area. This restaurant had its fish flown in from Italy and used its own storage warehouse, located off site, in order to provide a controlled supply of its menu items. We again advised on the layout and structure of this warehouse and also provided food safety management systems for the warehouse and control of the product’s transportation both from the airport to the storage facility and then again from the storage facility to the restaurant.

Using HACCP UK’s services permitted this restaurant to open in a short time period and also to gain a 5 star rating upon inspection from Westminster Council, who are renowned to be the strictest food safety authority in the world.

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Food Warehouse Facility

Scope: To provide documented food safety management systems to ensure good practice was being followed by all staff and to attract new clients.

We audited and then carried out gap analysis to create documented food safety management systems for a food warehouse that was providing food products, consisting of Ambient, Chilled and Frozen foods, including high risk and lower risk products, to restauranteurs, caterers and smaller food retailers around the entire London area.

This service enabled them to easily manage their day to day operations and also to gain new customers as with their documented food safety management systems now in place; they could prove the safety and quality of their food warehousing and delivery operations to their customers, including existing and also to attract new customers.

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Pet Food Packaging Facility

This client required all of their product lines to undergo the HACCP process and staff to receive relevant training in order to maintain the systems themselves.

We carried an audit of their site and product lines and then HACCP plans were written for each production line, together with their more generic goods in and goods out operations. We also advised on storage, GMP and structure where necessary too Staff received small group level 2 food safety training and level 2 HACCP training and then intense HACCP familiarisation days so that they could manage their own HACCP systems themselves, once we had created the systems for them.

Using HACCP UK’s services enabled this packing facility to comply with Trading Standard’s legislative requirements and the client to gain a foothold in new markets for their area of expertise. They are now considering moving into manufacturing their own products and again will be using HACCP UK’s services.

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Beware of Foodborne Bacteria - Listeria (see sidepanel on right of page)

bacillus bacteria

As a food producer, you have to have a documented food safety management system in place with an integral HACCP by law. A comprehensive and well considered food safety management system with a robust HACCP will benefit all concerned, including your customers (present and future), your staff and you. This is because a robust HACCP etc., will provide confidence in your systems and the safety of your food to all concerned parties, particularly you.

Contact HACCP UK for your HACCP system now !

Foodborne Bacteria Listeria

The most commonly known strain of listeria is L. monocytogenesListeria Image

With an incubation period of between three and seventy days, this bacteria could potentially be in your product infecting consumers for that period before you have any warning your product is contaminated.

Listeria is the name of a bacteria found in soil and water and in some animals, including poultry and cattle. It can be present in raw milk and foods made from raw milk. It can also live in the general environment of food processing plants and contaminate a variety of processed meats.

Listeria is unlike many other bacteria because it can grow even in the cold temperature of the refrigerator. Listeria can be killed by cooking and pasteurisation.

Sources of Listeria include:

  • Ready-to-eat deli meats and hot dogs
  • Refrigerated pâtés or meat spreads
  • Unpasteurised (raw) milk and dairy products
  • Soft cheese made with unpasteurised milk, Feta, Brie, Camembert
  • Refrigerated smoked seafood
  • Raw sprouted seeds

Symptoms:

  • Miscarriage of the unborn foetus*
  • Fever
  • Stiff neck
  • Confusion
  • Weakness
  • Vomiting

The above syptoms may also sometimes be preceded by diarrhoea.

Most at risk:

  • Pregnant women
  • Cancer sufferers
  • People with renal disease
  • Diabetics
  • HIV Aids sufferers
  • Older adults

*Listeria and Pregnancy

Listeriosis, an infection caused by Listeria monocytogenes which can pose major risks during pregnancy. Pregnant women are approximately 20 times more likely than other healthy adults to get listeriosis. In pregnant women, it is typically a mild flu-like illness that is suffered. For the unborn child however the effects may be far more severe.

First trimester:

  • May cause miscarriage

Third trimester:

  • Premature labour
  • Low birth weight
  • Infant death

Infected newborns may develop:

  • Mental retardation
  • Paralysis
  • Seizures
  • Blindness
  • Impairments of the brain, heart or kidney