Developing Non-Food HACCP capability at KDC/ONE

RI Training has completed a bespoke two-day Non-Food HACCP Developer programme for a newly formed HACCP team at KDC/ONE’s Wellington site.

KDC/ONE is a leading global manufacturer specialising in custom beauty and personal-care products.

The programme was commissioned to support a comprehensive review of the site’s existing HACCP arrangements. Its principal objective was to develop the knowledge, skills and confidence of the new multidisciplinary HACCP team, enabling its members to review, revise and strengthen the company’s HACCP plans.

Rather than focusing solely on theory, the programme was designed to help participants apply HACCP principles directly to their own products, processes and working environment.

The first workshop was delivered in December and introduced the team to the core principles of HACCP and the principal tools for developing and reviewing a HACCP plan.

Particular attention was given to how established HACCP principles can be applied in a non-food manufacturing environment and adapted to the potential hazards associated with beauty and personal care products.

Quality Manager Marlena Walecki had carefully selected a new multidisciplinary HACCP team comprising eight participants from different areas of the business.

Bringing together people with different responsibilities and perspectives is an important part of effective HACCP development. No single individual is likely to possess all the technical, operational and quality knowledge needed to evaluate every product and process effectively.

The multidisciplinary nature of the KDC/ONE team proved invaluable. Participants engaged fully in the workshop and made thoughtful, relevant contributions based on their respective areas of experience.

The first day covered subjects including:

• Establishing the scope of a HACCP study.
• Defining the product and its intended use.
• Constructing and confirming process-flow diagrams.
• Identifying and describing potential hazards.
• Considering existing prerequisite programmes.
• Assessing the significance of identified hazards.
• Selecting appropriate control measures.
• Determining whether critical control points are required.
• Documenting the resulting HACCP plan.

Following the first workshop, participants were given a practical assignment.

The team was asked to undertake a critical review of the existing HACCP plans, applying the knowledge and development tools introduced during the workshop.

This provided an opportunity to put the learning into practice within a genuine workplace context. It also enabled participants to evaluate existing arrangements rather than treating HACCP development as a purely classroom-based exercise.

The team examined the plans critically, identified potential gaps and considered where changes could improve their clarity, accuracy and effectiveness.

RI Training returned to the Wellington site in January to deliver the second workshop.

During the session, participants presented the outcomes of their reviews. These presentations included:

• Gaps identified within the existing arrangements.
• Areas where requirements needed to be clarified.
• Opportunities to strengthen hazard descriptions and risk assessments.
• Proposed revisions to the existing HACCP plan.
• Recommendations for improving the associated controls and records.

The presentations generated constructive and informed discussion. Participants were able to explain their conclusions, challenge different interpretations and agree how the plans should be revised.

This collaborative process culminated in agreement on a new and updated version of the company’s HACCP plan.

Using a real review exercise in this way provides benefits that extend beyond completing the course. Participants develop a much deeper understanding of how HACCP operates in practice and how an effective review should be planned and conducted in a non-food manufacturing environment.

It also helps to establish an internal team capable of maintaining the system, responding to change and completing future reviews.

The second workshop also explored how the HACCP team could confirm that the revised arrangements were suitable and continued to operate effectively.

The group considered the differences between:

• Validation: obtaining evidence that the selected control measures can control the identified hazards.
• Verification: checking that the HACCP system is being implemented and operating as planned.
• Review: reconsidering the plan when products, processes, equipment, knowledge or other relevant circumstances change.

By applying these requirements to their own revised plan, participants could see how they contribute to a living management system rather than to a document prepared once and left unchanged.

The final stage of the programme required each participant to complete a 40-question multiple-choice assessment through the RI Learn Online platform.

All eight members of the KDC/ONE team achieved the required pass mark and were awarded the RI Training Level 3 Non-Food HACCP Developer certificate.

The outcome demonstrates how structured training, practical workplace application and collaborative review can create genuine organisational capability—not simply provide individual certification.

Patrick McDaniel, who delivered the programme, commented:

“The engagement and commitment of the KDC/ONE team were excellent throughout both workshops. Applying the development tools to their existing arrangements enabled the participants to consolidate their learning while producing something of direct value to the business.”

RI Training develops and delivers bespoke Non-Food HACCP programmes for organisations that manufacture personal-care products, cosmetics, car-care products, detergents, cleaning products, packaging, and other non-food goods.

Programmes can be tailored around an organisation’s own products and processes, enabling participants to develop practical skills while reviewing or creating genuine workplace HACCP plans.

To discuss developing Non-Food HACCP capability within your organisation, please contact RI Training.