ensuring food quality & safety through multifaceted programs · 2015. 6. 12. · food,...
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Ensuring Food Quality & Safety Through Multifaceted
ProgramsPrograms
Bhadriraju Subramanyam (Subi), PhDProfessorProfessorDepartment of Grain Science and IndustryKansas State UniversityM h KS 66506Manhattan, KS 66506E-mail: [email protected]: www.oznet.ksu.edu/grsc_subip g _
What is Food?What is Food?
• Articles consumed by humans and animalsanimals
• Includes chewing gum and drinking water
What is Wholesome Food?What is Wholesome Food?
• Nutritionally balanced• Food without defects
What is Safe Food?What is Safe Food?
• Food that does not causeFood that does not cause injury or harm when consumed by humans or
gh
animals
wH
ig
• Trust is placed in food manufacturer to produce
Losafe food
• Consumers are unaware of dangers with food!
Adulterated FoodAdulterated Food
• Food containing poisonous or deleteriousFood containing poisonous or deleterious substances
Basis for HACCP– Basis for HACCP• Food containing added poisonous or
d l t i b tdeleterious substances• Food containing filth from animal or vegetable
matter• Food prepared under unsanitary conditions
– Basis for Good Manufacturing Practices
Before You Do Anything:Identify Th H dThe Hazards
• Hazards:a Physical peeling paint rust glass metala. Physical- peeling paint, rust, glass, metal,
wood or plasticb Ch i l l b i t ti idb. Chemical- grease, lubricants, pesticides,
allergens, condensationc. Biological- insects, microorganisms,
rodents, birds, and their by-products
H dHazards
• Likelihood of occurrence – High, Medium, Low
• Severity of occurrence– High, Medium, Lowg , ,
Severity of occurrence
H M L
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H HH HM HL
curr
ence
M MH MM ML
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L LH LM LL
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How Does a Food Manufacturer C b H d ?Combat Hazards?
• Multifaceted programs taking a holistic view of a food plant from the outside inview of a food plant from the outside in
St l k d li t !• Stop, look and listen!
• Seek root cause analysis on eliminating “cause” and not reacting to symptomsg y p
Remember We Have Laws To F ll !Follow!
• Food laws help ensure unadulterated product during food manufacturingproduct during food manufacturing
• Complying with the laws is good businessTh i ti f t i• Theory: prescriptive=> manufacturing flexibility=>innovation in plant equipment
d d iand design
B F d LBasic Food Laws
• Good Manufacturing Practices (GMPs) • Hazard Analysis and Critical Control Points• Hazard Analysis and Critical Control Points
(HACCP) Program P ti f d f t– Preventive food safety program
– Critical point vs Critical control point
UNDERSTANDING AND INTERPRETING FOOD SAFETY STANDARDS(GMP Example)
What is the language? How will the company comply
How will the company assure compliance
110.10 Personnel(a) Disease control. Any person who, by medical examination or supervisory
110.10 Personnel(a) Disease control. Employees who are sick or have open wounds, sores,
110.10 Personnel(a) Disease control.
observation, is shown to have, or appears to have, an illness, open lesion, including boils, sores, or infected wounds, or any other abnormal source of microbial contamination by which there
boils, or bandages on such wounds, shall report such conditions to their supervisor, and must not work with food, food-contact surfaces, or food packaging materials
A form showing which employee was excluded in performing operations, the date, and time, and employee’s reassigned duties if not absent.
microbial contamination by which there is a reasonable possibility of food, food-contact surfaces, or food packaging materials becoming contaminated, shall be excluded from any operations which
packaging materials.
Number of employees excluded by month from a particular operation.
may be expected to result in such contamination until the condition is corrected. Personnel shall be instructed to report such health conditions to their supervisors.supervisors.
What is the language? How will the company comply
How will the company assure compliancep y p
110.20 Plants and grounds.( ) G d Th d b f d
110.20 Plants and grounds( ) G d Th d di
110.10 Plants and grounds.( ) G d(a) Grounds. The grounds about a food
plant…….limited to:(a) Grounds. The grounds surrounding the food plant will be made of concrete and maintained in such a fashion so as to eliminate food contaminants.
(a) Grounds.
Daily inspection of the food plant exterior (a form is needed for this)
(1) Properly storing equipment, removing litter and waste, and cutting weeds or grass within the immediate vicinity of the plant buildings or
(1) Equipment cannot be stored on grounds. All equipment must be stored in the equipment storage shed on grated shelves. The perimeter of the f d l ill h 2 f i
A separate form showing when roads were repaired, shrubs, and bushes were trimmed.
vicinity of the plant buildings or structures that may constitute an attractant, breeding place, or harborage for pests.
food plant will have a 2-ft vegetation-free barrier zone. Shrubs and trees will be trimmed at established schedules and inspected for rodent and insect activity.
(2) Maintaining roads, yards, and parking lots so that they do not
y
(2) All roads shall be paved kept in good repair.
constitute a source of contamination in areas where food is exposed
Table I: Number and percent of recall actions by industry (N=1146)1999-2003
Industry No. recall actions PercentBakery products 217 18.94%Fishery/seafood products 135 11 78%Fishery/seafood products 135 11.78%Bean/vegetable products 88 7.68%Multiple food dinner products 85 7.42%Non-chocolate candy products 75 6.54%Fruit products 66 5.76%Ice cream products 62 5.41%pChocolate products 50 4.36%Snack food products 48 4.19%Beverage/beverage base products 38 3 32%Beverage/beverage base products 38 3.32%Cheese products 29 2.53%All other products 253 22.07%Total 1146 100%
Recall actions by specific processor-level problems (N=1146)
Proactive Versus Reactive Food Industry Programs
• Proactive, you’re a hero! Reactive, you’re a scapegoat!scapegoat!– Knowledge, intent, and foreseeability
• Prevent ALL “pest” harborages by sanitary• Prevent ALL pest harborages by sanitary design and program designK l d h i hb !• Know your plant and thy neighbors!
• Must have personal accountability– Attitude to do the right thing
P V RProactive Versus Reactive
• People, people, people- food plant is a p p pcommunity
• People make mistakes!• Are people adequately
trained to do the job?– Education– Training
B ll E A h O dBulls Eye Approach-Outside
• Outside- farthest away and work toward plant
a. Perimeter secured/fenced?
b Neighbors good andb. Neighbors- good and bad
c. Wind patterns, sun exposure on building
d. Landscaping
B ll E A h O dBulls Eye Approach-Outside
e. Pest interceptors such as rodent bait stations/traps or insect pheromone trapsstations/traps or insect pheromone traps
f. Paved lots; eliminate standing water R f th l d t kg. Roof areas- smooth, clean, ductwork, gutters
Rats and MiceRats and Mice• Family Muridae has 500 species• Rats and mice of SE Asia include:Rats and mice of SE Asia include:
– Rice field rat, Rattus argentiventer– The black rat, Rattus rattus diardii– The wood rat, Rattus tiomanicusThe wood rat, Rattus tiomanicus– The Norway rat, Rattus norvegicus– Little Malay rat, Rattus exulans– Greater bandicoot rat Bandicota indica
R. argentiventer (GR Singleton)
Greater bandicoot rat, Bandicota indica– House mouse, Mus musculus (several
subspecies)• Pelage: Vibrissae (long stiff hairs). Guard hairs
i i /i / d /i dg ( g )
– Protect from cold; tactile feedback; wetness; defense
www.irri.org/irrc/rodents/index.asp
M. musculus
Features• Nocturnal in habit• Excellent swimmers• Good climbers• Good sense of smell and hearing• Can gnaw through materials like leadCan gnaw through materials like lead
sheathing, aluminum, wood, wiring, etc
• Can enter through very smallCan enter through very small openings
• Tail– Variable length furry scaly or– Variable length, furry, scaly, or
bare– Cools the animal
Prehensile– Prehensile– Provides balance
Rodent Control Fights Hunger!Rodent Control Fights Hunger!Continent Production Gained No. extra Percentage of
(Million tons)
production (Million tons)
people nourished (Millions)
Undernourished benefiting
A i 1086 46 54 32 217 3 39Asia 1086.46 54.32 217.3 39Latin America 156.70 7.74 31.3 60
Africa 113.66 5.68 22.7 11Europe 37.70 1.89 7.5 26
Total (world) 1394.52 69.73 278.8 34
Includes all cereals in 113 countries where undernourishment exists.Includes all cereals in 113 countries where undernourishment exists.
Source: Meerburg, BG, GR Singleton, and H Leirs. 2009. The year of the rat ends–time to fight hunger! Pest Manag. Sci. 65: 351-352.
Unsanitary conditions outdoors
Building Exterior
Have an 2 ft vegetation free barrier zone
Shrubs too close to buildingg
Bait StationsBait StationsBait StationsBait Stations
BBBaitsBaits
TrapsTraps
Bi dBi dBirdsBirdsPigeon
E li h H SPigeon
E li h H SEnglish or House SparrowEuropean Starling
English or House SparrowEuropean StarlingEuropean StarlingEuropean Starling
Bi d M tBi d M tBird ManagementBird Management• Exclusion• RepellentsRepellents
Non-chemicalCh i lChemical
• Trapping
E l iE l iExclusionExclusion
Exclusion tactics
E l iE l iExclusionExclusion
Repellents
B ll E A h O dBulls Eye Approach-Outside
h. Lighting- mercury vapor highly attractive versus metal halide; illuminate back ontoversus metal halide; illuminate back onto building; never above doors or air intakes
i Dock/rail/personnel doors/windowsi. Dock/rail/personnel doors/windowsj. Storage areas- protected, up off ground,
ll tno palletsk. Building seams
Pest entry pointsPest entry points
B ll E A h I dBulls Eye Approach-Inside
• Start at receiving a Dock/waste areasa. Dock/waste areasb. Light traps, pheromone traps, rodent
t l i t i f ilcontrol, air curtain failuresc. Any need to separate/segregate employees
for microbial control?d. Shoe/Uniform programp g
A good pest exclusion practice
Improper stocking or storage practices
Give 12 inches of space betweenGive 12 inches of space betweenthe wall and palletsPallets, 6 inches off the floor
B ll E A h I dBulls Eye Approach-Inside
e. Restroom/locker rooms- slanted top of lockers no personal food storage periodiclockers, no personal food storage, periodic locker cleanouts/pest control
f Product flow raw materials in one end andf. Product flow- raw materials in one end and finished product out the otherP iti ti ig. Positive versus negative air pressure
Poor Sanitation
Spillage
Prevent unsanitary conditions
Sanitary Design AspectsSanitary Design Aspects
Sanitary Design AspectsSanitary Design Aspects
Building Interior: Unsanitary Conditions
Flat surfaces
Storage of unused equipment
Clean or avoid flat surfacesDi d d iDiscard unused equipment
Rate Rate Facility Facility Infestation By Infestation By L i f S i iL i f S i iLocation for SanitationLocation for Sanitation
P b bilit f i f st ti d t l ssP b bilit f i f st ti d t l ssSevereSevere HighHigh ModerateModerate LowLow
Probability of infestation or product lossProbability of infestation or product loss
DailyDaily ProductionProductionAreas; receivingAreas; receiving
FloorsFloors
WeeklyWeeklyuenc
yue
ncy
yy
MonthlyMonthly Spouts; Spouts; conditionerconditioner
BathroomsBathrooms
ing
freq
uin
g fr
equ
YearlyYearly Building Building exteriorexteriorCl
ean
Clea
n
EEquipment
• What type of product is produced?- dry, wet caustic acidic or perishablewet, caustic, acidic, or perishable
• Risks- meat, seafood, juices are regulatedW t d l d l COP CIP• Wet or dry cleaned, manual, COP, CIP, vacuum, air
EEquipment
• Is there a cross-functional member equipment review/approval program?q p pp p g
• No unprotected glass• Ceilings/overheads- no ledges false ceilingCeilings/overheads no ledges, false ceiling
trap• Food contact surfaces-corrosion resistant,Food contact surfaces corrosion resistant,
non-porous, non-absorbent, and non-puddlingp g
EEquipment
• Easy, quick disassembly and accessible• Micro/allergen cleanable and verifiable• Micro/allergen cleanable and verifiable• No hollow areas• Design aspects: continuous welds versus
stitch
IInspections
• Not a waste of time; must know plant inside and outand out
• Multidisciplinary in membership team, cross train rotate document deficienciescross-train, rotate, document deficiencies observe for proper follow upCl th l t j t “li t” t• Close the loop; not just a “list” creator; understand reasons for problems
IInspections
• Develop checklists
• Take corrective action/develop a preventive solutionsolution
• No third party inspector should inspect your• No third party inspector should inspect your plant and find an un-inspected area by the teamteam
Master Sanitation/Cleaning S h d lSchedules
• Daily versus non-daily; weekly, monthly, quarterly, semi-annual and annualq y,
• Only way you can answer question: “when was the last time this was cleaned?”
• Leave no space blank• Keep it simpleKeep it simple• Floor drains• Evaluate and determine economic benefits• Evaluate and determine economic benefits
Preventive Maintenance and W k O dWork Orders
• Simple and document
• Filters, sifters, strainers, lubricants, magnets d t l d t tand metal detectors
P l E d TPeople, Equipment and Training
• Proper people doing the proper job with the proper equipment and documented trainingproper equipment and documented training
• Money driven but be careful how you phrase message to employees (motivation)phrase message to employees (motivation)
Management Systems for Product Safety
• Organization• Vendor Specifications
• Employee Training• Preventive Cleaningp
• QC Programs/Lab Access/Sampling
• IPM programs• Management Self-Inspection
• Receiving Programs• Preventive
Program• Consumer Complaint/Recall
Maintenance/Equipment Specifications
Program• HACCP
Organization
• Clearly defined charts
Cl li f• Clear lines of responsibilities/Accountability
• Trained Staff
O C i ti• Open Communication
• Team Effort
“If you want 100% safety you have to stopIf you want 100% safety, you have to stop eating….”
Dr. Marion NestleDr. Marion NestleProfessor of NutritionNew York University
A Food Manufacturer ShouldA Food Manufacturer Should….
M it i di t lit• Monitor ingredient quality• Keep an inventory of ingredients/additives
C l i h l d d• Comply with regulatory standards • Coordinate delivery fleets• Institute preventive maintenance programs• Be computer literate• Manage and motivate people• Keep abreast of technology and the changing
consumer• It is not an easy task!
Subi’s Proactive Approaches for Food SafetyFood Safety
A h 1Approach 1
• Government-based inspection systems will not assure food safetyy– FDA in US inspects only 1% of the total food – A good-self inspection program is necessary– Focus on effective inspections rather than on more
inspections Use your four senses during inspection– Use your four senses during inspection
• Sight• Touch• Hearing• Smell
A h 2Approach 2
• Examine current trends in food consumptionconsumption– The frequency of any type of food safety issue
is based on food trends and eating habitsis based on food trends and eating habits
A h 3Approach 3
• Your basic programs should be fundamentally strongfundamentally strong– GMPs and HACCP
Not only at the processing facility but also– Not only at the processing facility but also along the farm to table continuum
A h 4Approach 4
• Analyze food safety risks with your product and allocate resources and systems toand allocate resources and systems to manage the risks (prioritize risks)– Apply risk-based criteria to regulatory andApply risk-based criteria to regulatory and
inspection efforts
A h 5Approach 5
• Design and implement better food safety systemssystems– ISO 22000:2005 international standard
Evolution beyond HACCP (5 + 7 steps)– Evolution beyond HACCP (5 + 7 steps)– All standards followed should be auditable!
Auditing vs inspection– Auditing vs inspection– Work on the process not the product (conduct
gap analysis)gap analysis)
A h 6Approach 6
• Educate all who handle and consume your productproduct– Food safety does not stop at your company
Food safety is a farm to table concept– Food safety is a farm to table concept
A h 7Approach 7
• Expand partnerships– Government alone cannot guarantee food safety– Government alone cannot guarantee food safety– Establish public-private-government
partnershipspartnerships
A h 8Approach 8
• Follow international food safety standards– Prevents duplication of effort– Prevents duplication of effort– Enhances sharing of information
Reduces multiple audits and inspections– Reduces multiple audits and inspections
A h 9Approach 9
• Enhance economic incentives to embrace food safetyfood safety– Cost of recalls is expensive
A h 10Approach 10
• Insist on supplier quality performance– Melamine in pet food– Melamine in pet food– Melamine in milk
Melamine in Rabbit candy– Melamine in Rabbit candy– Peanut Corporation of America (Salmonella)
S l ll i i t hi– Salmonella in pistachios
Thank You