Food Safety Quality Management Training Course

Participants can prepare accurate product descriptions and process flow diagrams for hazard analysis.

• Product descriptions covering ingredients, packaging, shelf life and intended use
• Intended consumers identified, including vulnerable groups and misuse risks
• Process flow diagrams built from receiving through dispatch
• On-site flow diagram confirmation against actual production activities
• Rework, waste, by-products and outsourced processes included systematically
• Process changes assessed before implementation using food safety criteria

Participants can identify and evaluate food safety hazards at each process step.

• Biological hazards assessed: pathogens, spoilage organisms and parasite risks
• Chemical hazards assessed: residues, cleaning chemicals, toxins and contaminants
• Physical hazards assessed: glass, metal, plastic and foreign material
• Allergen cross-contact pathways identified through process and material review
• Severity and likelihood ratings applied using defined risk matrices
• Existing controls evaluated for effectiveness, reliability and failure modes

Participants can specify prerequisite programmes that provide the foundation for HACCP controls.

• Good hygiene practices covering personnel, visitors and protective clothing
• Cleaning and sanitation programmes based on soil, surface and chemical selection
• Pest management controls, site inspections and trend reporting
• Water, ice and compressed air quality assurance requirements
• Temperature control for receiving, storage, processing and transport
• Facility zoning, workflow and segregation preventing contamination transfer

Participants can develop HACCP plans using Codex principles and decision-making logic.

• Codex HACCP seven principles applied to mapped food processes
• Control measures selected for significant hazards at each step
• Critical control points determined using documented decision-tree logic
• Operational prerequisite programmes distinguished from critical control points
• HACCP team responsibilities, expertise requirements and meeting records
• Hazard analysis rationale documented for audit and technical review

Participants can define control limits, monitoring methods and corrective action procedures for critical controls.

• Critical limits established from regulations, validation data and specifications
• Monitoring frequencies matched to hazard severity and process capability
• Measurement methods selected for temperature, time, pH and metal detection
• Monitoring records designed for timely review and exception visibility
• Corrective actions separate product disposition from process restoration
• Escalation criteria defined for repeated deviations and serious failures

Participants can distinguish validation from verification and build evidence-based control assurance activities.

• Validation evidence confirms controls can achieve intended food safety outcomes
• Verification schedules test whether documented controls operate as planned
• Calibration programmes cover thermometers, scales, probes and detection equipment
• Sampling plans set locations, frequencies, acceptance criteria and actions
• Trend review identifies recurring control failures before product incidents
• Verification findings fed into HACCP review and management decisions

Participants can design microbiological and environmental monitoring arrangements appropriate to product risk.

• Microbiological criteria linked to raw materials, products and process hygiene
• Environmental monitoring zones defined around exposed product areas
• Swabbing plans select sites, methods, frequencies and response thresholds
• Indicator organisms interpreted alongside pathogen detection results
• Positive results investigated using product, process and sanitation evidence
• Sampling limitations considered when making product release decisions

Participants can establish allergen controls from supplier approval through label release.

• Allergen registers identify ingredients, rework, processing aids and packaging
• Segregation controls address storage, scheduling, utensils and personnel movement
• Validated cleaning methods remove allergen residues between production runs
• Label approval verifies ingredient declarations, claims and allergen statements
• Packaging line checks prevent incorrect labels and carton mix-ups
• Allergen incidents contained through traceability, risk assessment and communication

Participants can assess suppliers and establish risk-based controls for incoming food materials.

• Supplier approval criteria cover certification, specifications, history and risk
• Raw material specifications define safety, quality, legal and authenticity requirements
• Incoming checks verify temperature, integrity, documentation and identification
• Certificate of analysis review matched to material risk and claims
• Supplier performance scorecards track defects, deviations and responsiveness
• Material changes controlled through technical review and HACCP reassessment

Participants can design traceability systems and coordinate structured withdrawal and recall responses.

• One-step-back and one-step-forward traceability records linked to batch codes
• Mass balance reconciliation tests material inputs against finished product outputs
• Withdrawal and recall criteria based on consumer and legal risk
• Recall team roles, contact lists and decision authority documented
• Mock recall testing measures speed, completeness and communication quality
• Product disposition decisions recorded for recovered and affected stock

Participants can investigate food safety and quality failures using disciplined corrective action methods.

• Nonconformities classified by food safety, quality, legal and customer impact
• Containment actions protect consumers while investigations proceed
• Five Whys and fishbone diagrams identify plausible root causes
• Corrective action plans assign owners, deadlines, evidence and effectiveness checks
• Preventive actions address system weaknesses and recurring failure patterns
• CAPA records distinguish correction, corrective action and preventive action

Participants can plan, conduct and report internal audits against food safety management requirements.

• Risk-based audit programmes prioritise high-risk processes and recurring findings
• Audit plans define objectives, criteria, scope, timing and responsibilities
• Interview techniques obtain evidence without leading operational staff
• Objective evidence sampled from records, observations and staff explanations
• Findings written with requirement, evidence, risk and clear classification
• Follow-up audits verify corrective action completion and effectiveness

Participants can establish document and record controls that support traceability, audits and operational decisions.

• Document hierarchies distinguish policies, procedures, work instructions and forms
• Approval workflows control technical review, issue dates and authorised release
• Version control prevents obsolete procedures reaching production areas
• Record retention periods reflect legal, customer and product shelf-life requirements
• Electronic records assessed for access, integrity, backup and audit trails
• Document changes trigger training, communication and hazard control review

Participants can use quality data to identify variation, process drift and improvement priorities.

• Quality attributes translated into measurable product and process specifications
• Sampling plans balance inspection effort, risk and production volume
• Control charts distinguish common-cause variation from special-cause signals
• Process capability compared with specification limits and customer tolerances
• Pareto analysis prioritises recurring defects, complaints and rework causes
• Trend reports combine quality, safety and operational performance data

Participants can assess sanitation controls and identify hygienic design weaknesses affecting food safety.

• Sanitation standard operating procedures define preparation, cleaning and verification
• Cleaning chemistry matched to soils, surfaces, water hardness and contact time
• Pre-operational inspections verify equipment cleanliness before production release
• Hygienic design checks identify niches, drainage failures and inaccessible surfaces
• Cleaning validation distinguishes visual cleanliness from microbiological control
• Sanitation performance reviewed through swabs, inspections and trend analysis

Participants can prepare a site for regulatory inspection, customer assessment and certification audit.

• Regulatory inspection evidence organised around licences, records and product controls
• ISO 22000 requirements translated into site-level management system activities
• FSSC 22000 additional requirements reviewed for food fraud and defence
• Food fraud vulnerability assessments identify economically motivated adulteration risks
• Food defence plans address intentional contamination and site security
• Certification audit readiness assessed through gap analysis and action tracking

Participants can use management review inputs to prioritise food safety and quality system improvement.

• Management review inputs include audits, complaints, incidents and performance trends
• Key performance indicators connect food safety controls with operational outcomes
• Risk registers updated from supplier changes, process changes and findings
• Improvement priorities ranked by consumer risk, compliance exposure and feasibility
• Resource decisions cover staffing, training, equipment and verification capability
• Management review outputs assign actions, ownership, timing and follow-up

Participants can build, review and present a complete food safety quality management pack for a selected product or process.

• Product scope, intended use and process flow defined clearly
• Hazard analysis and HACCP controls justified with documented evidence
• Prerequisite programmes linked to identified contamination and quality risks
• Monitoring, verification and corrective action arrangements integrated coherently
• Traceability, recall, audit and CAPA controls reviewed for consistency
• Improvement plan presented with priorities, owners, measures and timescales