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www.freddyhirsch.co.za
Freddy Hirsch Nigeria
Food Safety Quality Program
Author:- Seyi ‘Fodunrin(2019)
www.freddyhirsch.co.za
Our Food Safety Concept
• The Freddy Hirsch Nigeria’s manufacturing
system is intentionally designed to account for
food safety at every process step.
• We understand and identified significant food
safety hazard inherent in our operation and
have installed preventive controls to minimize
the risk of hazards.
• Our food safety plan imbibes Hazard Analysis
and Risk-based preventive Controls to
measure and reduce the risk of contamination.
• HACCP and cGMP are incorporated in
system operations to ensure food is
manufactured, processed, packaged and stored
in hygienic conditions to stay safe,
wholesome, and without quality deterioration
within the declared shelf life.
WAREHOUSING
SECONDARY PACKAGING
PALLETIZING
QA/QC LABORATORY BLENDING OF PREMIX
BATCHING OF RAW MATERIALS
BLENDING OF RAW MATERIALS
SIFTING OF RAW MATERIALS
METAL DETECTOR
PACKAGING OF FINISHED PRODUCTS IN INNER LINERS (1° PACKAGING)
SEALING OF BAGS
OPRP 1QC
CCP 1
QC
QCQC
QC
QC
CCP 3
PRP
HCP
OPRP 2
CCP2
R&D LAB/NPD
RAW MATERIALSHCP
WAREHOUSING/
DISPATCH
HCP-Halal Control Point
CCP-Critical Control Point
PRP- Prerequisite Program
OPRP- Operational Prerequisite
Program
HACCP-BASED PROCESS FLOW
www.freddyhirsch.co.za
Our Quality System
• Our Quality system drives Quality
Assurance which encompasses totality of
raw materials and GMP verification through
finished product release, and Quality Control
which concerns actual manufacturing
parameters meeting set criteria.
• It is the intention of our Quality program to
design a system which protects the brand
from undue regulatory unrest, customers
dissatisfaction and protect the product from
needless variation.
www.freddyhirsch.co.za
Certification and Regulatory Stance
• Freddy Hirsch Nigeria is duly registered with the National Administration for Food
and Drug Administration and Control (NAFDAC) and has registered up to Ten (10)
flavor profiles since inception.
• Our plant is Halal Certified by HASDAT, a member of the International Halal Integrity
Alliance, IHIA, Malaysia.
• We have been part of the quarterly Mandatory And Conformance Assessment Program
(MANCAP) of the Standards Organisation of Nigeria (SON) with impressive
feedback from the Organisation hitherto.
• Under the provisions of the Factories Act of the Federal Republic of Nigeria, CAP F1
LFN 2004, Freddy Hirsch Nigeria was licensed to operate as a factory in 2016 with
certificate No 000823.
• As a regulatory and safety compliant company, we have had good relationship with the
major Regulatory Agencies including LASEPA, FMLP, State and Federal Heath and
Evironmental Ministries, and Ikeja Local Authorities where we operate.
www.freddyhirsch.co.za
Research and New Product Development
• Research ingredients are
carefully screened for
compliance to FHG internal
specifications/Food Safety
requirements, Halal Assurance
System provisions and local
regulatory requirement from the
product development stage.
• All approved samples are
formally ‘launched to live’ and
pre-commercialized for
Production schedule.
www.freddyhirsch.co.za
Analytical Capabilities
• We have functional Laboratories-
Chemical, Microbiogical and R&D,
where our skilled Analysts provide
analytical data on the quality of
product and production processes to
support Quality control in the HACCP
system.
• The Laboratory testing is important to
our research and development of new
products, choice/quality/safety of
ingredients, shelf-life studies,
regulatory compliance, and sensory
evaluation of products.
www.freddyhirsch.co.za
Laboratory Testing Parameters
In partnership with our third party Public
Analyst Laboratory and parent company in
South Africa; our range of analytical testing
covers:
• Physiochemical Analysis
• Total Afflatoxin B1,B2,G1,G2
• Microbiological Analysis
• Heavy Metal contaminant
www.freddyhirsch.co.za
Raw Material/Entrance Control Program
• Our first important commitment at
ensuring Total Quality
Management to our customers is to
seek ingredients from safe and
approved sources.
• Ingredients meeting up with raw
materials Receiving Policy and
Entrance protocol requirements of
the FHG are sampled for micro
organisms, physiochemical
characteristics, contaminants and
illegal additives.
www.freddyhirsch.co.za
Sifting of raw materials
• The Sifting gantry has
magnetic bars, and vibratory
Screener Russell compact
Sieve of unique particle size
for specific ingredients.
• The magnetic bars remove
metal impurities while the
screen removes any
observable physical hazard.
www.freddyhirsch.co.za
Blending
• A magnetic screen slit
functions to dispense
finished blend through a
control point into large tuff
bags.
• Machinery failures which
may be inform of broken
blades and nuts have been
considered for control at
this CCP.
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Packaging
• Just like in the Ribbon Blenders, the
packaging machine has magnetic
screens to trap metals and other
foreign matters of appreciable sizes.
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Metal Detection
• The food grade metal detector
machine is installed directly
after the packaging unit as an
Operational Pre-requisite
program, OPRP.
• Finished goods in its final stage
after packaging are checked
once again via an X-ray metal
detector system to fully
exclude any form of metal.
www.freddyhirsch.co.za
Good Manufacturing Practice
• As part of our moral responsibility
to produce safe and wholesome
foods to our customers, GMP forms
a vital prerequisite of our overall
food safety system.
• While our food safety culture places
emphasis on GMP without
compromise, our staffs are trained
and constantly retrained on our
GMP procedures.
www.freddyhirsch.co.za
Retention sampling
• Retention sample is kept
for each batch of
production and monitored
over the shelf life period.
• This verifies product shelf
life period, food quality,
microbiological, physical
and chemical attributes
intended to form the
overall product quality
characteristics in time.
www.freddyhirsch.co.za
Shelf Life Testing
• We also conduct Accelerated
Shelf Life testing, ASLT on
finished goods.
• This is usually conducted on
new products, and in the event
of recipe re-
formulation/modification or
alternate package evaluation to
predict future attributes and
anticipated degradation in time
over certain condition and
variables.
www.freddyhirsch.co.za
Integrated Pest Management
• As an important
prerequisite to the
existing food safety
program; an Integrated
Pest Management system
that uses an exciting and
modern technology is
being managed by
accredited pest
management partners.
• Rodent Bait stations and
UV-Insect light traps are
strategically located
across various units of the
facility.
www.freddyhirsch.co.za
Allergen Management
• At the moment, we cannot
completely guarantee an
“allergen free product” or a
“dedicated allergen status” on
our products, as we do not have
a request for allergen free
products yet.
• While we do not have a
dedicated allergen lines in our
factory, Cross contamination is
under control through system
line clearance.
• Allergen warning is advised in
prone areas while declaration
made on concerned products.
www.freddyhirsch.co.za
Product Recall and Traceability
• Our Recall program is integrated with Freddy Hirsch in-house UnityF8 ERP
software by Sanderson.
• Each raw material is allocated a barcode automatically linked to a specific order
number on the system.
• As the raw materials move through the various stages of the production process
the barcode is changed to reflect these changes and linked to the order number.
When the raw material is used in the manufacturing of a finished product, the
raw material barcode is scanned into a particular ‘works order’ (recipe) which
has a unique barcode associated to it.
• The works order reflects a unique batch number, which is also printed onto each
finished product label, thus enabling tracking of each of the raw materials
scanned into a particular recipe.
• While a Mock recall to verify our recall and traceability program is scheduled
for once per annum, no Mock recall is required if a successful recall has been
conducted during the course of the year.
• To effectively manage Recall, a team is established to handle in the company
and consumer’s best interest
www.freddyhirsch.co.za
Environmental Protection
• Freddy Hirsch Nigeria
recognizes that its operations are
capable of significant impact on
the environment, and therefore
commits to reducing potential
impact.
• One of the most advanced dust
pollution containment system
and best practices have been
adopted to reduce impact to as
low as reasonably possible.
www.freddyhirsch.co.za
THANK YOU
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